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July 2014

Rules for theManufacture,Testing andCertificationof Materials

A guide to the Rulesand published requirements

Rules for the Manufacture, Testing andCertification of Materials

Introduction

The Rules are published as a complete set; individual Parts are,however, available on request. A comprehensive List of Contentsis placed at the beginning of each Part.

Numbering and Cross-References

A decimal notation system has been adopted throughout. Fivesets of digits cover the divisions, i.e., Part, Chapter, Section, sub-Section and paragraph. The textual cross-referencing within the text is as follows, although the right hand digits maybe added or omitted depending on the degree of precisionrequired: (a) In same Chapter, e.g., see 2.1.3 (i.e., down to paragraph).(b) In another set of Lloyd’s Register Rules, e.g., see Pt 5,

Ch 3,2.1 of the Rules and Regulations for the Classificationof Ships.

The cross-referencing for Figures and Tables is as follows:(a) In same Chapter, e.g., as shown in Fig. 2.3.5 (i.e., Chapter,

Section and Figure Number). (b) In another set of Lloyd’s Register Rules, e.g., see

Table 2.7.1 in Pt 3, Ch 2 of the Rules and Regulations forthe Classification of Special Service Craft.

Rules updating

The Rules are generally published annually and changed througha system of Notices. Subscribers are forwarded copies of suchNotices when the Rules change.

Current changes to Rules that appeared in Notices are shownwith a black rule alongside the amended paragraph on the lefthand side. A solid black rule indicates amendments and a dotted black rule indicates corrigenda.

July 2014

Lloyd’s Register is a trading name of Lloyd’s Register Group Limited and its subsidiaries. For further details please see http://www.lr.org/entities

Lloyd's Register Group Limited, its affiliates and subsidiaries and their respective officers, employees or agents are, individually and collectively, referredto in this clause as ‘Lloyd's Register’. Lloyd's Register assumes no responsibility and shall not be liable to any person for any loss, damage or expensecaused by reliance on the information or advice in this document or howsoever provided, unless that person has signed a contract with the relevantLloyd's Register entity for the provision of this information or advice and in that case any responsibility or liability is exclusively on the terms and conditions set out in that contract.

Chapter ContentsRULES FOR THE MANUFACTURE, TESTING AND CERTIFICATION OF MATERIALS, July 2014

Materials

LLOYD’S REGISTER 1

RULES FOR THE MANUFACTURE, TESTING AND CERTIFICATION OF MATERIALS

CHAPTER 1 GENERAL REQUIREMENTS

2 TESTING PROCEDURES FOR METALLIC MATERIALS

3 ROLLED STEEL PLATES, STRIP, SECTIONS AND BARS

4 STEEL CASTINGS

5 STEEL FORGINGS

6 STEEL PIPES AND TUBES

7 IRON CASTINGS

8 ALUMINIUM ALLOYS

9 COPPER ALLOYS

10 EQUIPMENT FOR MOORING AND ANCHORING

11 APPROVAL OF WELDING CONSUMABLES

12 WELDING QUALIFICATIONS

13 REQUIREMENTS FOR WELDED CONSTRUCTION

14 PLASTICS MATERIALS AND OTHER NON-METALLIC MATERIALS

© Lloyd's Register Group Limited 2014. All rights reserved.

Except as permitted under current legislation no part of this work may be photocopied, stored in a retrieval system, published, performed in public, adapted, broadcast, transmitted, recorded or reproduced in any form or by any means, without the prior permission of the copyright owner. Enquiries should be addressed to Lloyd's Register Group Limited, 71 Fenchurch Street, London, EC3M 4BS.

ContentsRULES FOR THE MANUFACTURE, TESTING AND CERTIFICATION OF MATERIALS, July 2014

Materials


CHAPTER 1 GENERAL REQUIREMENTS

Section 1 Scope1.1 General

Section 2 Approval and survey requirements2.1 Approval and survey requirements – General2.2 LR Approval – General2.3 Materials Survey Scheme2.4 Materials Quality Scheme

Section 3 Certification of materials3.1 General3.2 Materials Survey Scheme3.3 Materials Quality Scheme3.4 Electronic certification

Section 4 General requirements for manufacture4.1 General4.2 Chemical composition4.3 Heat treatment4.4 Test material4.5 Mechanical tests4.6 Re-test procedures4.7 Rectification of defective material4.8 Identification of materials

Section 5 Non-destructive examination5.1 General NDE requirements5.2 Personnel qualifications5.3 Non-destructive examination methods5.4 Non-destructive examination procedures5.5 Non-destructive examination reports

Section 6 References6.1 General

CHAPTER 2 TESTING PROCEDURES FOR METALLIC MATERIALS

Section 1 General requirements for testing1.1 Preparation of test specimens1.2 Testing machines1.3 Discarding of test specimens1.4 Re-testing procedures

Section 2 Tensile tests2.1 Dimensions of test specimens2.2 Definition of yield stress for steel2.3 Procedure for testing at ambient temperature2.4 Equivalent elongations2.5 Procedure for testing at elevated temperatures

Section 3 Impact tests3.1 Dimensions of test specimens3.2 Testing procedures

Section 4 Ductility tests for pipes and tubes4.1 Bend tests4.2 Flattening tests4.3 Drift expanding tests4.4 Flanging tests


Materials

LLOYD’S REGISTER4

Section 5 Embrittlement tests5.1 Temper embrittlement tests5.2 Strain age embrittlement tests5.3 Hydrogen embrittlement tests

Section 6 Crack tip opening displacement tests6.1 Dimensions of test specimens6.2 Test equipment6.3 Testing procedures6.4 Validity requirements6.5 Test reports

Section 7 Bend tests7.1 Dimensions of test specimens7.2 Testing procedures

Section 8 Hardness testing8.1 Dimensions of test specimens8.2 Testing procedure

Section 9 Corrosion tests9.1 Intergranular corrosion test

CHAPTER 3 ROLLED STEEL PLATES, STRIP, SECTIONS AND BARS

Section 1 General requirements1.1 Scope1.2 Steel with guaranteed through thickness properties – ‘Z’ grade steel1.3 Corrosion resistant steels for cargo oil tanks of crude oil tankers1.4 Manufacture1.5 Quality of materials1.6 Dimensional tolerances1.7 Heat treatment1.8 Test material and mechanical tests1.9 Visual and non-destructive examination

1.10 Rectification of defects1.11 Identification of materials1.12 Certification of materials

Section 2 Normal strength steels for ship and other structural applications2.1 Scope2.2 Manufacture and chemical composition2.3 Condition of supply2.4 Mechanical tests2.5 Identification of materials2.6 Certification of materials

Section 3 Higher strength steels for ship and other structural applications3.1 Scope3.2 Alternative specifications3.3 Manufacture3.4 Chemical composition3.5 Condition of supply3.6 Mechanical tests3.7 Identification of materials3.8 Certification of materials


Materials


Section 4 Steels for boilers and pressure vessels4.1 Scope4.2 Manufacture and chemical composition4.3 Heat treatment4.4 Mechanical tests4.5 Identification of materials4.6 Certification of materials4.7 Mechanical properties for design purposes

Section 5 Steels for machinery fabrications5.1 General5.2 Certification of materials

Section 6 Ferritic steels for low temperature service6.1 Scope6.2 Manufacture and chemical composition6.3 Heat treatment6.4 Mechanical tests6.5 Identification of materials6.6 Certification of materials

Section 7 Austenitic and duplex stainless steels7.1 Scope7.2 Chemical composition7.3 Heat treatment7.4 Mechanical tests7.5 Metallographic examination for sigma phase7.6 Intergranular corrosion tests7.7 Clad plates7.8 Identification of materials7.9 Certification of materials

Section 8 Plates with specified through thickness properties8.1 Scope8.2 Manufacture8.3 Test material8.4 Mechanical tests8.5 Non-destructive examination8.6 Identification of materials8.7 Certification of materials

Section 9 Bars for welded chain cables9.1 Scope9.2 Manufacture9.3 Chemical composition9.4 Heat treatment9.5 Embrittlement tests9.6 Mechanical tests9.7 Structure and hardenability tests9.8 Dimensional tolerances9.9 Non-destructive examination

9.10 Identification9.11 Certification of materials

Section 10 High strength quenched and tempered steels for welded structures10.1 Scope10.2 Manufacture and chemical composition10.3 Mechanical properties10.4 Identification of materials10.5 Certification of materials


Materials

LLOYD’S REGISTER6

CHAPTER 4 STEEL CASTINGS

Section 1 General requirements1.1 Scope1.2 Manufacture1.3 Quality of castings1.4 Chemical composition1.5 Heat treatment1.6 Test material and test specimens1.7 Visual and non-destructive examination1.8 Pressure testing1.9 Rectification and dressing of castings

1.10 Identification of castings1.11 Certification of materials

Section 2 Castings for ship and other structural applications2.1 Scope2.2 Chemical composition2.3 Heat treatment2.4 Mechanical tests2.5 Non-destructive examination2.6 Acceptance levels for surface crack detection

Section 3 Castings for machinery construction3.1 Scope3.2 Chemical composition3.3 Heat treatment3.4 Mechanical tests3.5 Non-destructive examination

Section 4 Castings for crankshafts4.1 Scope4.2 Manufacture4.3 Chemical composition4.4 Heat treatment4.5 Mechanical tests4.6 Non-destructive examination4.7 Rectification of defective castings

Section 5 Castings for propellers5.1 Scope5.2 Chemical composition5.3 Heat treatment5.4 Mechanical tests5.5 Non-destructive examination5.6 Rectification of defective castings5.7 Identification5.8 Certification of materials

Section 6 Castings for boilers, pressure vessels and piping systems6.1 Scope6.2 Chemical composition6.3 Heat treatment6.4 Mechanical tests6.5 Non-destructive examination6.6 Mechanical properties for design purposes

Section 7 Ferritic steel castings for low temperature service7.1 Scope7.2 Chemical composition7.3 Heat treatment7.4 Mechanical tests7.5 Non-destructive examination


Materials


Section 8 Stainless steel castings8.1 Scope8.2 Chemical composition8.3 Heat treatment8.4 Mechanical tests8.5 Corrosion tests8.6 Non-destructive examination

Section 9 Steel castings for container corner fittings9.1 General9.2 Chemical composition9.3 Heat treatment9.4 Mechanical tests9.5 Non-destructive examination9.6 Repair of defects9.7 Identification9.8 Certification of materials

CHAPTER 5 STEEL FORGINGS

Section 1 General requirements1.1 Scope1.2 Manufacture1.3 Quality1.4 Chemical composition1.5 Heat treatment1.6 Test material1.7 Mechanical tests1.8 Visual and non-destructive examination1.9 Rectification of defects


Section 2 Forgings for ship and other structural applications2.1 Scope2.2 Chemical composition2.3 Heat treatment2.4 Mechanical tests2.5 Non-destructive examination

Section 3 Forgings for shafting and machinery3.1 Scope3.2 Chemical composition3.3 Heat treatment3.4 Mechanical tests3.5 Non-destructive examination

Section 4 Forgings for crankshafts4.1 Scope4.2 Manufacture4.3 Chemical composition4.4 Heat treatment4.5 Mechanical tests4.6 Non-destructive examination

Section 5 Forgings for gearing5.1 Scope5.2 Manufacture5.3 Chemical composition5.4 Heat treatment5.5 Mechanical tests for through hardened, induction hardened or nitrided forgings5.6 Mechanical tests for carburised forgings5.7 Non-destructive examination


Materials

LLOYD’S REGISTER8

Section 6 Forgings for turbines6.1 Scope6.2 Manufacture6.3 Chemical composition6.4 Heat treatment6.5 Mechanical tests6.6 Non-destructive examination6.7 Thermal stability tests

Section 7 Forgings for boilers, pressure vessels and piping systems7.1 Scope7.2 Chemical composition7.3 Heat treatment7.4 Mechanical tests7.5 Non-destructive examination7.6 Pressure tests7.7 Mechanical properties for design purposes

Section 8 Ferritic steel forgings for low temperature service8.1 Scope8.2 Chemical composition8.3 Heat treatment8.4 Mechanical tests8.5 Non-destructive examination8.6 Pressure tests

Section 9 Stainless steel forgings9.1 General9.2 Chemical composition9.3 Heat treatment9.4 Mechanical tests9.5 Mechanical properties for design purposes9.6 Non-destructive examination9.7 Corrosion tests

CHAPTER 6 STEEL PIPES AND TUBES

Section 1 General requirements1.1 Scope1.2 Manufacture1.3 Quality1.4 Dimensional tolerances1.5 Chemical composition1.6 Heat treatment1.7 Test material1.8 Dimensions of test specimens and test procedures1.9 Visual and non-destructive testing

1.10 Hydraulic test1.11 Rectification of defects1.12 Identification1.13 Certification of materials

Section 2 Seamless pressure pipes2.1 Scope2.2 Manufacture and chemical composition2.3 Heat treatment2.4 Mechanical tests2.5 Mechanical properties for design


Materials


Section 3 Welded pressure pipes3.1 Scope3.2 Manufacture and chemical composition3.3 Heat treatment3.4 Mechanical tests3.5 Mechanical properties for design

Section 4 Ferritic steel pressure pipes for low temperature service4.1 Scope4.2 Manufacture and chemical composition4.3 Heat treatment4.4 Mechanical tests

Section 5 Austenitic stainless steel pressure pipes5.1 Scope5.2 Manufacture and chemical composition5.3 Heat treatment5.4 Mechanical tests5.5 Intergranular corrosion tests5.6 Fabricated pipework5.7 Certification of materials

Section 6 Boiler and superheater tubes6.1 Scope6.2 Manufacture and chemical composition6.3 Heat treatment6.4 Mechanical tests6.5 Mechanical properties for design

CHAPTER 7 IRON CASTINGS

Section 1 General requirements1.1 Scope1.2 Manufacture1.3 Quality of castings1.4 Chemical composition1.5 Heat treatment1.6 Test material1.7 Mechanical tests1.8 Visual and non-destructive examination1.9 Rectification of defective castings

1.10 Pressure testing1.11 Identification of castings1.12 Certification of materials

Section 2 Grey iron castings2.1 Scope2.2 Test material2.3 Mechanical tests

Section 3 Spheroidal or nodular graphite iron castings3.1 Scope3.2 Heat treatment3.3 Test material3.4 Mechanical tests3.5 Metallographic examination

Section 4 Compacted or vermicular graphite iron castings4.1 Scope4.2 Heat treatment4.3 Test material4.4 Mechanical tests4.5 Metallographic examination


Materials

LLOYD’S REGISTER10

Section 5 Iron castings for crankshafts5.1 Scope5.2 Manufacture5.3 Heat treatment5.4 Test material5.5 Non-destructive examination5.6 Rectification of defective castings5.7 Certification of materials

CHAPTER 8 ALUMINIUM ALLOYS

Section 1 Plates, bars and sections1.1 Scope1.2 Manufacture1.3 Quality of materials1.4 Dimensional tolerances1.5 Chemical composition1.6 Heat treatment1.7 Test material1.8 Mechanical tests1.9 Corrosion tests

1.10 Pressure weld tests1.11 Visual and non-destructive examination1.12 Rectification of defects1.13 Identification1.14 Certification of materials

Section 2 Aluminium alloy rivets2.1 Scope2.2 Chemical composition2.3 Heat treatment2.4 Test material2.5 Mechanical tests2.6 Tests from manufactured rivets2.7 Identification2.8 Certification of materials

Section 3 Aluminium alloy castings3.1 Scope3.2 Manufacture3.3 Quality of castings3.4 Chemical composition3.5 Heat treatment3.6 Mechanical tests3.7 Visual examination3.8 Rectification of defective castings3.9 Pressure testing


Section 4 Aluminium/steel transition joints4.1 Scope4.2 Manufacture4.3 Visual and non-destructive examination4.4 Mechanical tests4.5 Identification4.6 Certification of materials


Materials


CHAPTER 9 COPPER ALLOYS

Section 1 Castings for propellers1.1 Scope1.2 Manufacture1.3 Quality of castings1.4 Chemical composition1.5 Heat treatment1.6 Test material1.7 Mechanical tests1.8 Inspection and non-destructive examination1.9 Rectification of defective castings

1.10 Weld repair procedure1.11 Identification1.12 Certification of materials

Section 2 Castings for valves, liners and bushes2.1 Scope2.2 Manufacture2.3 Quality of castings2.4 Chemical composition2.5 Heat treatment2.6 Test material2.7 Mechanical tests2.8 Inspection2.9 Rectification of defective castings

2.10 Pressure testing2.11 Identification2.12 Certification of materials

Section 3 Tubes3.1 Scope3.2 Manufacture3.3 Quality3.4 Dimensional tolerances3.5 Chemical composition3.6 Heat treatment3.7 Mechanical tests3.8 Visual examination3.9 Hydraulic test

3.10 Rectification of defects3.11 Identification3.12 Certification of materials

CHAPTER 10 EQUIPMENT FOR MOORING AND ANCHORING

Section 1 Anchors1.1 Scope1.2 Manufacture1.3 Cast steel anchors1.4 Forged steel anchors1.5 Fabricated steel anchors1.6 Rectification1.7 Super high holding power (SHHP) anchors1.8 Assembly1.9 Proof test of anchors

1.10 Clearances and tolerances1.11 Identification1.12 Certification


Materials


Section 2 Stud link chain cables for ships2.1 Scope2.2 Manufacture2.3 Flash butt welded chain cable2.4 Cast chain cables2.5 Forged chain cables2.6 Stud material2.7 Welding of studs2.8 Heat treatment of completed chain cables2.9 Testing of completed chain cables

2.10 Proof load tests2.11 Dimensional inspection2.12 Breaking load tests2.13 Fittings for chain cables2.14 Substitute single links2.15 Identification2.16 Certification

Section 3 Stud link mooring chain cables3.1 Scope3.2 Manufacture3.3 Dimensions and tolerances3.4 Studs3.5 Heat treatment of completed chain cables3.6 Testing of completed chain cables3.7 Connecting common links or substitute links3.8 Fittings for offshore mooring chain3.9 Identification

3.10 Documentation3.11 Certification

Section 4 Studless mooring chain cables4.1 Scope4.2 Manufacture4.3 Shape and dimensions of links4.4 Dimensional tolerances4.5 Heat treatment4.6 Testing of completed chain4.7 Connecting or substitute links4.8 Fittings4.9 Identification

4.10 Certification4.11 Documentation

Section 5 Short link chain cables5.1 Scope5.2 Manufacture5.3 Bar material5.4 Testing and inspection of chain cables5.5 Dimensions and tolerances5.6 Identification5.7 Certification

Section 6 Steel wire ropes6.1 Scope6.2 General requirements6.3 Steel wire for ropes6.4 Tests on completed ropes6.5 Inspection6.6 Identification6.7 Certification


Materials


Section 7 Fibre ropes7.1 Manufacture7.2 Tests of completed ropes7.3 Identification7.4 Certification

CHAPTER 11 APPROVAL OF WELDING CONSUMABLES

Section 1 General1.1 Scope1.2 Grading1.3 Manufacture1.4 Approval procedures1.5 Annual inspection and tests1.6 Changes in grading1.7 Manufacturers’ Quality Assurance Systems1.8 Certification

Section 2 Mechanical testing procedures2.1 Dimensions of test specimens2.2 Testing procedures2.3 Re-testing procedures

Section 3 Electrodes for manual and gravity welding3.1 General3.2 Deposited metal test assemblies3.3 Butt weld test assemblies3.4 Hydrogen test3.5 Fillet weld test assemblies3.6 Electrodes designed for deep penetration welding3.7 Deep penetration butt weld test assemblies3.8 Deep penetration fillet weld test assemblies3.9 Electrodes designed for gravity or contact welding

3.10 Annual tests

Section 4 Wire-flux combinations for submerged-arc automatic welding4.1 General4.2 Approval tests for multi-run technique4.3 Deposited metal test assemblies (multi-run technique)4.4 Butt weld test assemblies (multi-run technique)4.5 Approval tests for two-run technique4.6 Butt weld test assemblies (two-run technique)4.7 Annual tests

Section 5 Wires and wire-gas combinations for manual, semi-automatic and automatic welding5.1 General5.2 Approval tests for manual and semi-automatic multi-run welding5.3 Approval tests for multi-run automatic welding5.4 Approval tests for two-run automatic welding5.5 Annual tests

Section 6 Consumables for use in electro-slag and electro-gas welding6.1 General6.2 Butt weld test assemblies6.3 Annual tests

Section 7 Consumables for use in one-side welding with temporary backing materials7.1 General7.2 Approval tests for manual (m), semi-automatic (S) and automatic multi-run (M) techniques7.3 Approval tests for high heat input automatic (A) techniques7.4 Annual tests


Materials


Section 8 Consumables for welding austenitic and duplex stainless steels8.1 General8.2 Deposited metal test assemblies8.3 Butt weld test assemblies8.4 Fillet weld test assemblies8.5 Annual tests

Section 9 Consumables for welding aluminium alloys9.1 General9.2 Approval tests for manual, semi-automatic and automatic multi-run techniques9.3 Deposited metal test assembly9.4 Butt weld test assemblies9.5 Fillet weld test assembly9.6 Approval tests for two-run technique9.7 Butt weld test assemblies (two-run technique)9.8 Annual tests

CHAPTER 12 WELDING QUALIFICATIONS

Section 1 General qualification requirements1.1 General1.2 Design1.3 Materials1.4 Performance of welding tests

Section 2 Welding procedure qualification tests for steels2.1 General2.2 Welding variables2.3 Steel test assemblies2.4 Welding of steel test assemblies2.5 Non-destructive examination (NDE)2.6 Destructive tests – General requirements2.7 Destructive tests for steel butt welds2.8 Destructive tests for steel fillet welds2.9 Destructive tests for T, K, Y steel nozzle welds

2.10 Destructive tests for steel pipe branch welds2.11 Destructive tests for weld cladding of steel2.12 Mechanical test acceptance criteria for steels2.13 Failure to meet requirements (Retests)2.14 Test records2.15 Range of approval2.16 Welding procedure specification (WPS)

Section 3 Specific requirements for stainless steels3.1 Scope3.2 Austenitic stainless steels3.3 Duplex stainless steels3.4 Martensitic stainless steels

Section 4 Welding procedure tests for non-ferrous alloys4.1 Requirements for aluminium alloys 4.2 Requirements for copper alloys

Section 5 Welder qualification tests5.1 Scope5.2 Welder qualification test assemblies5.3 Examination and testing5.4 Acceptance criteria5.5 Failure to meet requirements5.6 Range of approval5.7 Welders qualification certification


Materials


Section 6 Qualification of friction stir welding of aluminium alloys6.1 Scope6.2 Welding equipment6.3 Weld procedures6.4 Qualification of welding operators

CHAPTER 13 REQUIREMENTS FOR WELDED CONSTRUCTION

Section 1 General welding requirements1.1 Scope1.2 Design1.3 Materials1.4 Requirements for manufacture and workmanship1.5 Cutting of materials1.6 Forming and bending1.7 Assembly and preparation for welding1.8 Welding equipment and welding consumables1.9 Welding procedure and welder qualifications

1.10 Welding during construction1.11 Non-destructive examination of welds1.12 Routine weld tests1.13 Rectification of material defects1.14 Rectification of distortion1.15 Rectification of welds defects1.16 Post-weld heat treatment1.17 Certification

Section 2 Specific requirements for ship hull structure and machinery2.1 Scope2.2 Welding consumables2.3 Welding procedure and welder qualifications2.4 Construction and workmanship2.5 Butt welds2.6 Lap connections2.7 Closing plates2.8 Stud welding2.9 Fillet welds

2.10 Post-weld heat treatment2.11 Tolerances2.12 Non-destructive examination of welds2.13 Weld repairs2.14 Welding afloat with water backing

Section 3 Specific requirements for fabricated steel sections3.1 Scope3.2 Dimensions and tolerances3.3 Identification of products3.4 Manufacture and workmanship3.5 Non-destructive examination3.6 Routine weld tests3.7 Certification and records


Materials


Section 4 Specific requirements for fusion welded pressure vessels4.1 Scope4.2 Cutting and forming of shells and heads4.3 Fitting of shell plates and attachments4.4 Welding4.5 General requirements for routine weld production tests4.6 Production test plate assembly requirements4.7 Inspection and testing4.8 Mechanical requirements4.9 Failure to meet requirements

4.10 Post-weld heat treatment4.11 Basic requirements for post-weld heat treatment of fusion welded pressure vessels4.12 Non-Destructive Examination of welds4.13 Extent of NDE for Class 1 pressure vessels4.14 Extent of NDE for Class 2/1 pressure vessels4.15 NDE Method4.16 Evaluation and reports4.17 Repair to welds

Section 5 Specific requirements for pressure pipework5.1 Scope5.2 Manufacture and workmanship5.3 Heat treatment after bending of pipes5.4 Post-weld heat treatment5.5 Non-destructive examination5.6 Repairs to pipe welds

Section 6 Repair of existing ships by welding6.1 Scope6.2 Materials used for repairs6.3 Workmanship6.4 Non-destructive examination6.5 Repairs to welds defects

Section 7 Austenitic and duplex stainless steel – Specific requirements7.1 Scope7.2 Design7.3 Forming and bending7.4 Fabrication and welding7.5 Repairs

Section 8 Specific requirements for welded aluminium8.1 Scope8.2 Forming and bending8.3 Fabrication and welding8.4 Non-destructive examination

Section 9 Friction stir welding requirements for aluminium alloys9.1 Scope9.2 Production quality control9.3 Repair


Materials


CHAPTER 14 PLASTICS MATERIALS AND OTHER NON-METALLIC MATERIALS

Section 1 General requirements1.1 Scope1.2 Information on material quality and application1.3 Manufacture1.4 Survey procedure1.5 Alternative survey procedure1.6 Post-cure heating1.7 Test material1.8 Re-test procedure1.9 Visual and non-destructive examination

1.10 Rectification of defective material1.11 Identification of products and base materials1.12 Certification

Section 2 Tests on polymers, resins, reinforcements and associated materials2.1 Scope2.2 Thermoplastic polymers2.3 Thermosetting resins2.4 Reinforcements2.5 Reinforced thermoplastic polymers2.6 Reinforced thermosetting resins2.7 Core materials2.8 Specific requirements for end-grain balsa2.9 Specific requirements for rigid foams (PVC, Polyurethane and other types)

2.10 Synthetic felt type materials with or without microspheres2.11 Machinery chocking compounds (resin chocks)2.12 Rudder and pintle bearings2.13 Sterntube bearings2.14 Plywoods2.15 Adhesive and sealant materials2.16 Repair compounds

Section 3 Testing procedures3.1 General3.2 Preparation of test samples3.3 Preparation of test specimens3.4 Testing3.5 Discarding of test specimens3.6 Reporting of results3.7 Tests for specific materials3.8 Structural core materials3.9 Machinery chocking compounds

3.10 Rudder and pintle bearings3.11 Sterntube bearings

Section 4 Plastics pipes and fittings4.1 Scope4.2 Design requirements4.3 Manufacture4.4 Quality assurance4.5 Dimensional tolerances4.6 Composition4.7 Testing4.8 Visual examination4.9 Hydraulic test

4.10 Repair procedure4.11 Identification4.12 Certification


Materials


Section 5 Control of material quality for composite construction5.1 Scope5.2 Design submission5.3 Construction5.4 Quality assurance5.5 Dimensional tolerances5.6 Material composition5.7 Material testing5.8 Visual examination5.9 Repair procedure

5.10 Material identification5.11 Minimum tested requirements for material approval5.12 Closed cell foams for core construction based on PVC or polyurethane5.13 End-grain balsa5.14 Synthetic chocking compounds5.15 Other materials

■ Section 2Approval and survey requirements

2.1 Approval and survey requirements – General

2.1.1 Marine materials manufactured in accordance withChapters 3 to 10 of these Rules are to be made at workswhich have been approved by LR for the type and grade ofproduct being supplied.

2.1.2 Materials manufactured in accordance withChapters 3 to 10 of these Rules are to be manufactured,tested and inspected under Survey according to the require-ments of one of the following two schemes:(a) The Materials Survey Scheme, see 2.3.(b) The Materials Quality Scheme, see 2.4.

2.1.3 For the purposes of survey, LR Surveyors are to beallowed access to all relevant parts of the works, and are tobe provided with the necessary facilities and information toenable them to verify that the manufacture is being carried outin accordance with the approved procedures. Facilities arealso to be provided for the selection of test material, thewitnessing of mechanical tests and the examination of materials, as required by these Rules.

2.1.4 Where a production process, testing or examina-tion of materials is sub-contracted, this must be with theapproval of LR. Surveyors are to be allowed access to thesub-contractor’s premises in order to conduct Surveysaccording to the requirements of these Rules.

2.1.5 Products manufactured in accordance withChapters 11 and 14 are to be approved in accordance withthe requirements therein. For these materials, approval isgiven for a specific product on a type approval basis, ratherthan the approved manufacturer/survey arrangements appliedto materials covered by Chapters 3 to 10.

2.2 LR Approval – General

2.2.1 Unless specifically stated in other Chapters of theseRules, all LR approvals apply to materials used in applicationsintended for marine service, as described in 1.1.

2.2.2 The procedures for application for approval ofmanufacturers and products, the details of the information tobe supplied by the manufacturer, and the test programme tobe conducted on the products are given in the appropriatebook of LR’s Materials and Qualification Procedures for Ships(MQPS). This is published in the CD Live section of LR’s website at http://www.lr.org.

Section

1 Scope

2 Approval and survey requirements

3 Certification of materials

4 General requirements for manufacture

5 Non-destructive examination

6 References

■ Section 1Scope

1.1 General

1.1.1 Materials used for the construction, conversion,modification or repair of ships, other marine structures andassociated machinery which are classed or are intended forclassification by Lloyd’s Register (hereinafter refered to as LR),are to be manufactured, tested and inspected in accordancewith these Rules.

1.1.2 Wrought, cast and extruded materials are tocomply with the requirements of Chapters 1 and 2, and theappropriate specific requirements of Chapters 3 to 9 of theseRules. Mooring and anchoring equipment is to comply withthe requirements of Chapters 1 and 2, and the appropriatespecific requirements of Chapter 10. Manufacturers of thesematerials must be approved by LR according to the require-ments in Sections 2 or 3. Only those materials within amanufacturer’s scope of approval may be used.

1.1.3 Welding consumables are to comply with therequirements of Chapter 11 of these Rules.

1.1.4 Where welding is used for the construction, conversion, modification or repair of ships, other marine structures and associated machinery which are classed or areintended for classification by LR, welding qualifications andtests shall be performed according to Chapter 12 of theseRules. All welding shall be performed according to Chapter13 of these Rules.

1.1.5 Plastics materials are to comply with the require-ments of Chapter 14 of these Rules.

1.1.6 The materials and components which are tocomply with these requirements for the purposes of classifi-cation are defined in the relevant Rules dealing with designand construction.

General RequirementsRULES FOR THE MANUFACTURE, TESTING AND CERTIFICATION OF MATERIALS, July 2014

Chapter 1Sections 1 & 2


2.2.13 Any documents, data or other information receivedas part of the approval process, will be treated as strictly confidential, and will not be disclosed to any third party, without the manufacturer’s prior written consent.

2.2.14 The approved works will be subject to a periodicinspection of all relevant parts of the works, at intervals notexceeding three years. The procedure for this periodicinspection is given in Book B of LR’s Materials andQualification Procedures for Ships (MQPS). This periodicinspection is in addition to the regular visits made accordingto 2.3.7.

2.3 Materials Survey Scheme

2.3.1 Materials according to Chapters 3 to 10 of theseRules and produced under the Materials Survey Scheme willbe subject to Direct Survey by an LR Surveyor. The schemerequires the Surveyor to survey and certify all materialsaccording to the requirements of these Rules.

2.3.2 Approved manufacturers are to request a survey ofthe material by an LR Surveyor, when required. Manufacturersmust provide the Surveyor with details of the order, specification and any special conditions additional to therequirements of these Rules.

2.3.3 All mechanical tests required by these Rules are tobe witnessed. The Surveyor may allow part of this task to becarried out by a member of the works staff by prior writtenagreement.

2.3.4 Before final acceptance, all materials are to besubmitted to the specified tests and examinations underconditions acceptable to the Surveyor. The results are tocomply with the Rules, and all materials are to be to the satisfaction of the Surveyor.

2.3.5 The specified tests and examinations are to becarried out prior to the despatch of finished materials from themanufacturer’s works. Where materials are supplied in therough or unfinished condition, as many as possible of thespecified tests are to be carried out by the manufacturer, andany tests or examinations that are not completed are to becarried out under survey at a subsequent stage of manufacture.

2.3.6 In the event of any material proving unsatisfactoryduring subsequent working, machining or fabrication, suchmaterial is to be rejected, notwithstanding any previous certification.

2.3.7 In addition to witnessing test results, the Surveyoris responsible for ensuring that the manufacturing process,inspection, testing, identification and certification are properlyconducted. As part of the Materials Survey Scheme, regularvisits will be made to all relevant parts of the works to checkfor compliance against the requirements of these Rules, andto ensure that the manufacturer is maintaining the capabilityto consistently produce approved materials.

2.3.8 The Surveyor, when satisfied that the material fullymeets the requirements of these Rules, will certify the materialin accordance with Section 3 and the appropriate Chapter ofthese Rules.

General Requirements

2.2.3 LR publishes lists of approved manufacturers andapproved products. The lists are published in the CD Livesection of LR’s website, http://www.lr.org.The lists are as follows:• List of Approved Manufacturers of Materials.• Approved Welding Consumables for Use in Ship

Construction.• Lists of Paints, Resins, Reinforcements and Associated

Materials.• Lists of Approved Anchors.

2.2.4 For initial LR approval as an Approved Manufacturerfor a particular material, the manufacturer is required todemonstrate to the satisfaction of LR, that the necessarymanufacturing and testing facilities are available, and aresupervised by suitably qualified personnel. A specifiedprogramme of tests is to be carried out under the supervisionof LR Surveyors, and the results are to be to the satisfactionof LR.

2.2.5 If the results of the initial assessment of the manufacturer, and the test programme are considered satisfactory, the manufacturer will be added to the list ofapproved manufacturers of materials, and a certificate ofapproval will be issued to the manufacturer by LR, showingthe scope of materials and grades covered by the approval.Initial approval will generally be under the Materials SurveyScheme, see 2.3.

2.2.6 Approved manufacturers who meet the entryrequirements, may apply for approval under the MaterialsQuality Scheme, see 2.4.

2.2.7 When a manufacturer has more than one works,the manufacturer’s approval shall only be valid for the workswhere the test programme was conducted.

2.2.8 It is the manufacturer’s responsibility to advise LR ofall changes to the manufacturing process parameters thatmay affect the application of the material, prior to the adoptionof the changes in production. Additional approval tests maybe required to maintain the approval.

2.2.9 Maintenance of approval is dependent on themanufacturer continuing to meet the requirements of theapplicable sections of these Rules.

2.2.10 Where it is considered that an approved manufac-turer is not maintaining its responsibilities to comply withthese Rules, the approval may be suspended by LR until suchtime that agreed corrective and preventive actions are considered to have been satisfactorily carried out. If considered necessary, LR may require that the normal levelof testing and inspection is increased.

2.2.11 In all instances, LR will reduce the scope of, or withdraw approval from, a manufacturer where it becomesapparent that the manufacturer is unable to maintain compliance with these Rules, or the scope of approval.

2.2.12 Where a manufacturer disagrees with any decisionsmade with regard to LR approval, they may appeal in writingto LR.

RULES FOR THE MANUFACTURE, TESTING AND CERTIFICATION OF MATERIALS, July 2014

Chapter 1Section 2

LLOYD’S REGISTER2

2.4 Materials Quality Scheme

2.4.1 The manufacturer may apply to be approved underthe Materials Quality Scheme, where the following require-ments are met:(a) The manufacturer has been approved by LR for a

minimum of three years and continues to maintain theirLR works approval according to 2.2.14; and

(b) The manufacturer has a quality management system,which has been certified as meeting the requirements ofISO 9001 by a certification body recognised by LR,which is one accredited by a member of the InternationalAccreditation Forum; and

(c) The manufacturer has a satisfactory history of qualityperformance in the manufacture and supply of LRapproved materials.

2.4.2 Special consideration may be given to manufacturerswho have not been approved under the Materials SurveyScheme, and may be considered onto the Materials QualityScheme providing:(a) They have a quality management system, which has

been certified as meeting the requirements of ISO 9001by a certification body recognised by LR, which is oneaccredited by a member of the International AccreditationForum.

(b) They can demonstrate a history of satisfactory supply ofmaterials, which LR deems to be equivalent to those forwhich approval under the Materials Quality Scheme isrequested.

In this case, the initial assessment of the manufacturer willinclude the product testing regime, as required for initialapproval under the Materials Survey Scheme, see 2.2.4.

2.4.3 The Scheme is based on a Scheme CertificationSchedule, made between LR and each individual manufacturer. The schedule will stipulate:(a) The scope of approved products covered by the

approval.(b) The process route applied by the manufacturer for each

approved product.(c) The arrangements for LR scheme, audits, including

scope, frequency, schedule, etc.(d) Agreed procedures for certification of approved

materials.(e) Information to be supplied periodically to LR by the

manufacturer.(f) Procedures for the use of the scheme mark.

2.4.4 The contents of the Scheme Certification Scheduleare to remain confidential between LR and the manufacturer.

2.4.5 The Materials Quality Scheme is based on a technical audit approach, and is designed to complement thequality management systems audits performed to ISO 9001.The role of the Surveyor in scheme audits is to:(a) Verify that the quality management system is being

maintained and audited to the requirements of ISO 9001.

(b) Verify that the requirements of these Rules are beingimplemented.

(c) Verify that the requirements of this Scheme are beingimplemented.


(d) Perform Scheme audits, which focus on the technicalaspects of the product realisation process, particularlywith regard to Rule requirements.

(e) Perform witness testing as required.(f) Verify the data supplied to LR periodically by the

manufacturer, as part of the Scheme requirements.

2.4.6 The Materials Quality Scheme may be applied toany approved manufacturer who meets the eligibility require-ments, and who applies to be approved under the scheme. Ifapproved under the scheme, the manufacturer’s name willappear on the List of Approved Manufacturers published byLR, with an indication that they are approved under thisscheme.

2.4.7 The scheme is available to manufacturers producingapproved materials according to Chapters 3 to 10 of theseRules.

2.4.8 The procedures for application for approval for theMaterials Quality Scheme are given in Book M of LR’sMaterials and Qualification Procedures for Ships (MQPS).

2.4.9 Where LR is satisfied that the manufacturer meetsall of the requirements of the Scheme, and that it is appropriate for the products being manufactured, a SchemeCertification Schedule will be issued, which must be signedby an authorised representative of the manufacturer.

2.4.10 Once the Scheme Certification Schedule has beensigned by both parties, LR will issue the manufacturer with acertificate of approval according to the Materials QualityScheme.

2.4.11 Maintenance of approval will be according to theScheme Certification Schedule, agreed between LR and themanufacturer, and these Rules.

2.4.12 It is the responsibility of the attending Surveyor, toperform regular Scheme audits at the manufacturer’s worksin accordance with the Scheme Certification Schedule, andthe requirements of these Rules.

2.4.13 It is not the intention to repeat the audit accordingto ISO 9001, conducted by the recognised certification body.The Surveyor is, however, to be satisfied that these audits arebeing conducted effectively. Where appropriate, the Surveyormay conduct a partial audit to ISO 9001 to verify this.

2.4.14 Witness tests may be conducted as part of theScheme audit. This will involve the selection of material, andthe witness of sampling and testing according to the require-ments of the appropriate chapter of these Rules. Suchwitness testing may be on LR grades, or materials which theSurveyor deems to be equivalent (for the purposes of audittesting only).

2.4.15 Once every three years, a full assessment ofscheme compliance will be conducted by a Surveyor who isnot the regular attending Surveyor. This assessment is in addition to the periodic inspection requirement made according to 2.2.14.


Chapter 1Section 2



2.4.16 In the event of any change, which means that themanufacturer no longer meets the requirements for theMaterials Quality Scheme (for example the loss of ISO 9001approval), the Scheme certificate of approval will be revoked.The manufacturer will revert to the Materials Survey Scheme,and will be subject to survey according to that scheme.

■ Section 3Certification of materials

3.1 General

3.1.1 All materials subject to these Rules are to besupplied with appropriate certification, as required by the relevant requirements of these Rules. This will normally be aLR certificate or a manufacturer’s certificate validated by LR,although a manufacturer’s certificate may be accepted whereallowed by the relevant requirements of these Rules.

3.1.2 Manufacturers approved under the MaterialsQuality Scheme are licensed to apply the scheme mark tomanufacturer’s certificates according to the requirements ofthe scheme, see 2.4.

3.1.3 The following certificate types are to be used, (a)and (b) for the Materials Survey Scheme, and (d) for theMaterials Quality Scheme:(a) LR Certificate

This type of certificate is issued by LR based on theresults of testing and inspection being satisfactorilycarried out in accordance with the requirements of theseRules.

(b) Manufacturer’s certificate validated by LRA manufacturer’s certificate, validated by LR on the basisof inspection and testing carried out by the manufacturerand which is in accordance with the requirements ofthese Rules, may be accepted. In this case, the certificate will include the following statement:“We hereby certify, that the material has been made byan approved process and satisfactorily tested in accordance with the Rules of Lloyd’s Register.”

(c) Manufacturer’s certificateThis type of certificate is issued by the manufacturer,based on the results of testing and inspection beingsatisfactorily carried out in accordance with the requirements of these Rules, or the applicable Nationalor International standard. The certificate is to be validated by the manufacturer’s authorised representa-tive, independent of the manufacturing department. Thecertificate will contain a declaration that the products arein compliance with the requirements of these Rules orthe applicable National or International standard.

(d) Manufacturer’s certificate issued under the MaterialsQuality SchemeWhere a manufacturer is approved according to theMaterials Quality Scheme, they will issue manufacturer’scertificates bearing the scheme mark. The certificatesmust also bear the following statement:“This certificate is issued under the arrangements authorised by Lloyd’s Register (operating group) inaccordance with the requirements of the MaterialsQuality Scheme and scheme number MQS ……..”

3.1.4 Where these Rules allow for the issue of a manu-facturer’s certificate for materials, either validated by an LRSurveyor, or bearing the Materials Quality Scheme mark, themanufacturer is to ensure that a copy of the certificate issupplied to LR.

3.2 Materials Survey Scheme

3.2.1 The requirements for certification of materialsaccording to the Materials Survey Scheme, are establishedby the relevant requirements of these Rules.

3.2.2 The manufacturer is to supply the surveyor with anyadditional customer order requirements that are in addition tothe requirements of these Rules, when the request for theissue or validation of the certificate is made.

3.3 Materials Quality Scheme

3.3.1 Part of the certification schedule, will include anagreement for the manufacturer, to apply the scheme markto manufacturer’s certificates, relating to approved productswithin the scope of approval of the manufacturer.

3.3.2 The use of the scheme mark is governed by thefollowing:(a) The use of the scheme mark is not transferable. It is only

to be used in conjunction with the manufacturer andworks name and location shown on the certificate ofapproval.

(b) The scheme mark must be applied to all manufacturers’certificates relating to approved materials producedunder the Scheme.

(c) In no circumstances is the scheme mark to be applied totest certificates relating to non-approved products.

(d) The scheme mark is not to be used in any way whichmay imply approval for products which are not coveredwithin the manufacturer’s scope of approval.

(e) Where a manufacturer is removed or suspended from thescheme, use of the scheme mark must cease immediately.

3.3.3 The certificate as given in 3.1.3(d) is to be validatedby an authorised representative of the manufacturer. The sizeand position of the scheme mark and statement on the manufacturer’s certificate must be agreed by LR.

3.3.4 Where manufacturers are approved under thisscheme, the manufacturer’s certificate, issued according tothese requirements, fully meets the materials certificationrequirements of these Rules.

3.4 Electronic certification

3.4.1 Where these Rules allow the issue of manufacturers’test certificates, under either the Materials Survey Scheme orthe Materials Quality Scheme, these may be issued in electronic format provided that:(a) All tests and inspections have been satisfactorily

completed, according to the requirements of theseRules.



LLOYD’S REGISTER4


(b) Procedures are in place to ensure that electronic certificates are only issued, according to the require-ments of these Rules.

(c) The certification system is subject to regular inspectionby the attending Surveyor.

(d) A copy of the electronic certificate is supplied to LR. Thiscopy will be deemed to be the original of the test certificate.

3.4.2 In addition to the requirements of 3.4.1, for itemscertified under the Materials Survey Scheme, the LR officestamp and Surveyor’s name may be applied electronically. Thisis only allowed where the Surveyor has access to the results ofthe relevant tests and inspections, and is able to authorise byaccess to the electronic system, the application of the LR officestamp and Surveyor’s name on the test certificate. The name ofthe authorising Surveyor is to be the name included on thecertificate. The authorisation may be conducted electronicallyeither at the manufacturers’ works, or remotely by the Surveyor.

3.4.3 If the LR office stamp and name are being appliedelectronically according to 3.4.2, then the manufacturer is toensure that the Surveyor is provided with all relevant informa-tion regarding the customer order, when the request forauthorisation is made.

■ Section 4General requirements formanufacture

4.1 General

4.1.1 The following definitions are applicable to theseRules:Item: A single forging, casting, plate, tube or other

rolled product as delivered.Piece: The rolled product from a single slab or billet or

from a single ingot if this is rolled directly intoplates, strip, sections or bars.

Batch: A number of similar items or pieces presentedas a group for acceptance testing.

Wide flat: Flat product of a width over 150 mm, up to andincluding 1250 mm and thickness generallyover 4 mm. Edges are square cut, i.e., hotrolled on the four sides. Supplied in lengths,not coils.

Plate/sheet: Flat rolled product whereby the edges areallowed to deform freely. Supplied flat andgenerally in square or rectangular shapes witha width of 600 mm or over, but other shapesmay also apply.

4.1.2 Where a manufacturer purchases semi-finishedproducts (e.g., slabs) for the purpose of re-processing (e.g.,rolling), the manufacturer is to ensure that the materials arefrom an LR approved manufacturer, and manufactured withinthe scope of approval of that manufacturer. The aim ofchemical analysis, dimensions, surface and internal qualitychecks are to be agreed between the manufacturer andpurchaser. The semi-finished materials must be supplied withappropriate certification, according to these Rules.

4.1.3 It is the responsibility of the manufacturer, to ensurecompliance with all relevant aspects of these Rules. Alldeviations are to be recorded as non-compliances, andbrought to the attention of the Surveyor, along with correctiveactions taken. Failure to do this is considered to render thematerial as not complying with these Rules.

4.1.4 The manufacturer is to maintain all test and inspectionrecords required by these Rules for at least seven years.Records are to be made available to LR on request.

4.1.5 Where material is produced which does not meetall aspects of these Rules, the manufacturer may apply to LRfor a concession to certify the material as approved. LR willconsider each application on a case-by-case basis, althoughconcession will only normally be granted in exceptionalcircumstances. If the concession is granted, a formal writtennumbered concession will be issued to the manufacturer. Theconcession number must be applied to the approval certificate,whether it is an LR certificate or a validated manufacturer’scertificate.

4.2 Chemical composition

4.2.1 The ladle analysis used for certification purposes isto be determined after all alloying elements have been addedand sufficient time allowed for such additions to equalisethroughout the ladle.

4.2.2 The method of taking samples is to ensure that thereported analysis is representative of the cast. In addition, themanufacturer must determine and certify the chemicalcomposition of every heat of material.

4.2.3 Where more than one sample is taken, the methodof averaging for the final certificate result and the determinationof acceptable variations in composition are to be agreed withthe Surveyor.

4.2.4 The chemical composition of ladle samples is to bedetermined by the manufacturer in an adequately equippedand competently staffed laboratory. The manufacturer’sanalysis will be accepted, but may be subject to occasionalindependent checks if required by the Surveyor.

4.2.5 The analysis is to include the content of all theelements detailed in the relevant Sections of the Rules and,where appropriate, the National or International Standardapplied.

4.2.6 At the discretion of the Surveyors, a checkchemical analysis of suitable samples from products may alsobe required. These samples are to be taken from the materialused for mechanical tests but, where this is not practicable,an alternative procedure for obtaining a representative sampleis to be agreed with the manufacturer. For product samples,the permissible limits of deviation from the specified ladleanalysis are to be in accordance with an appropriateInternational or National Standard specification.





4.3 Heat treatment

4.3.1 Materials are to be supplied in the conditionspecified in, or permitted by, the relevant Chapters of theseRules.

4.3.2 Heat treatment is to be carried out in properlyconstructed furnaces, which are efficiently maintained andhave adequate means for control and recording oftemperature. The furnace dimensions are to be such as toallow the whole item to be uniformly heated to the necessarytemperature. In the case of very large components, whichrequire heat treatment, alternative methods will be speciallyconsidered.

4.3.3 The manufacturer is to maintain the records,including the temperature charts of all heat treatments, for atleast seven years.

4.4 Test material

4.4.1 Sufficient test material is to be provided for thepreparation of the test specimen detailed in the specificrequirements. It is, however, in the interests of manufacturersto provide additional material for any re-tests which may benecessary, as insufficient or unacceptable test material maybe a cause for rejection.

4.4.2 The test material is to be representative of the itemor batch and is not to be separated until all the specified heattreatment has been completed, except where provision for analternative procedure is made in subsequent Chapters ofthese Rules.

4.4.3 All test material is to be selected by the Surveyoror an authorised deputy and identified by suitable markingswhich are to be maintained during the preparation of the testspecimens.

4.5 Mechanical tests

4.5.1 The dimensions, number and direction of testspecimens are to be in accordance with the requirements ofChapter 2 and the specific requirements for the product.

4.5.2 Where Charpy impact tests are required, a set ofthree test specimens is to be prepared and the averageenergy value is to comply with the requirements ofsubsequent Chapters. One individual value may be less thanthe required average value, provided that it is not less than 70 per cent of that value.

4.5.3 In the Rules, mechanical properties are specified inSI units, but alternative units may be used for acceptancetesting. In such cases, the specified values are to beconverted in accordance with the appropriate conversionsgiven in Table 1.4.1. It is preferred that test results bereported in SI units, but alternative units may be usedprovided that the test certificate gives, in the same units, theequivalent specification values.

4.6 Re-test procedures

4.6.1 Re-test procedures are to be in accordance withthe requirements of Ch 2,1.4.

4.7 Rectification of defective material

4.7.1 Small surface imperfections may be removed bymechanical means provided that, after such treatment, thedimensions are acceptable, the area is proved free fromdefects and the rectification has been completed inaccordance with any applicable requirements of subsequentChapters of these Rules and to the satisfaction of theSurveyor.

4.7.2 The repair of defects by welding, can be acceptedonly when permitted by the appropriate specific requirementsand provided that the agreement of the Surveyor is obtainedbefore the work is commenced. When a repair has beenagreed, it is necessary in all cases to prove by suitablemethods of non-destructive examination that the defects havebeen completely removed before welding is commenced.Welding procedures and inspection on completion of therepair, are to be in accordance with the appropriate specificrequire-ments and are to be to the satisfaction of the Surveyor.

4.7.3 Manufacturers wishing to carry out welding workmust have at their disposal the necessary workshops, liftinggear, welding equipment, pre-heating, and where necessaryannealing facilities and testing devices, as well as certifiedwelders and supervisors to enable them to perform the workproperly. Proof shall be furnished to the Surveyor that theseconditions are satisfied before welding work begins.

4.8 Identification of materials

4.8.1 The manufacturer is to adopt a system ofidentification, which will enable all finished materials to betraced to the original cast, and the Surveyors are to be givenfull facilities for tracing the material when required. When anyitem has been identified by the personal mark of a Surveyor,or his deputy, this is not to be removed until an acceptablenew identification mark has been made by a Surveyor. Failureto comply with this condition will render the item liable torejection.


Chapter 1Section 4

LLOYD’S REGISTER6

1 N/mm2 or MPa = 0,102 kgf/mm2

1 N/mm2 or MPa = 0,0647 tonf/in2

1 N/mm2 or MPa = 0,145 x 103 lbf/in2

1J = 0,102 kgf m1J = 0,738 ft lbs

1 kgf/mm2 = 9,81 N/mm2 or MPa1 tonf/in2 = 15,4 N/mm2 or MPa1 lbf/in2 = 6,89 x 10–3 N/mm2 or MPa

1 kgf m = 9,81 J1 ft lbf = 1,36 J

Table 1.4.1 Conversions from SI units to metricand Imperial units


4.8.2 Before any item is finally accepted, it is to be clearlymarked by the manufacturer in at least one place with theparticulars detailed in the appropriate specific requirements.

4.8.3 Where hard stamps such as the LR brand stampare issued to manufacturers to carry out the stamping onbehalf of LR, the procedure for issue, maintenance and useof stamps is to be agreed in writing.

4.8.4 Hard stamping is to be used except where thismay be detrimental to the material, in which case stencilling,painting or electric etching is to be used. Paints used toidentify alloy steels are to be free from lead, copper, zinc ortin, i.e., the dried film is not to contain any of these elementsin quantities of more than 250 ppm.

4.8.5 Where a number of identical items are securelyfastened together in bundles, the manufacturer need onlybrand the top item of each bundle. Alternatively, a durablelabel giving the required particulars may be attached to eachbundle.

■ Section 5Non-destructive examination

5.1 General NDE requirements

5.1.1 Prior to the final acceptance of materials, surfaceinspection and verification of dimensions, non-destructiveexamination is to be carried out in accordance with therequirements detailed in this Section and subsequent Chaptersof these Rules.

5.1.2 It is the manufacturer’s responsibility for maintainingthe required tolerances and making the necessary measure-ments. Periodic surveys by the Surveyor do not absolve themanufacturer from this responsibility.

5.1.3 When there is visible evidence to doubt thesoundness of any material or component, such as flaws in testspecimens or suspicious surface marks, the manufacturer isexpected to prove the quality of the material by a suitablemethod.

5.1.4 Acceptance criteria are detailed in subsequentChapters of these Rules. Alternative specifications may besubmitted for consideration, provided they demonstrateequivalence to these Rules.

5.2 Personnel qualifications

5.2.1 The shipyard, fabricator or manufacturer is toensure that personnel carrying out non-destructiveexamination or interpreting the results of non-destructiveexamination are qualified to the appropriate level of anationally recognised scheme such as ISO 9712, PCN,ACCP or SNT-TC-1A. Level 1 personnel are not permitted tointerpret results to Codes or Standards.

5.2.2 When certification of personnel is made on an in-housebasis under a scheme such as SNT-TC-1A, practicalexaminations are to be relevant to material, product type,joint configuration, material thickness and acceptance criteriaof items inspected for Classification purposes.

5.2.3 Personnel qualifications of NDE operators are to berandomly checked by the Surveyor.

5.3 Non-destructive examination methods

5.3.1 Non-destructive examination methods are to complywith the relevant requirements of these Rules.

5.4 Non-destructive examination procedures

5.4.1 All non-destructive examinations are to be carriedout to a procedure that is representative of the item underinspection. As a minimum the procedures are to be inaccordance with the following:(a) Procedures are to identify the component to be

examined, the NDE method, equipment to be used andthe full extent of the examinations including any testrestrictions.

(b) Procedures are to specify the qualification and certification requirements of the inspection personnel tobe employed.

(c) Procedures are to state the degree of surface preparation required and the methods of preparation tobe used before the examinations are made.

(d) Procedures are to state the reference standards for testing and the acceptance criteria to be applied to theresults of the inspections.

(e) Procedures are to include the requirement for components to be positively identified and for a datumsystem or marking system to be applied to ensurerepeatability of inspections.

(f) Procedures are to identify any requirements for increasing the extent of applied NDE where defects havebeen found during spot examination.

(g) Procedures are to identify reporting requirements.(h) Procedures are to be reviewed by the Surveyor to ensure

they are appropriate for the product type.(j) Procedures for radiography are to specify the

acceptable optical density within the area of interest onthe radiograph.

(k) The minimum optical density within the area of intereston a radiograph is to be equal to or greater than 2,0 forgamma ray and 1,8 for X-ray. A maximum density of 4,0 is acceptable.

(l) Procedures are to include the method and requirementsfor equipment calibrations and functional checks.

(m) Procedures are to be approved by an operator qualifiedto a minimum of Level III in accordance with a recognised standard.

(n) The Surveyor will review procedures for compliance withthis Section.




Rule reference Standard

Chapter 1 – General ISO 9001: 2008Requirements SNT-TC-1A:2012

ISO 9712:2012

Chapter 2 – Testing ISO 6892-1: 2009Procedures for Metallic ISO 185: 2005Materials ISO 2566-1: 1999

ISO 148-1: 2009ISO 7500-1: 2004ISO 6506-1: 2006ISO 6506-2: 2006ISO 6506-3: 2006ISO 6507-1: 2006ISO 6507-2: 2006ISO 6507-3: 2006ISO 6508-1: 2006ASTM E23-Rev C (2012)

Chapter 3 – Rolled Steel EN 10160: 1999Plates, Strip, Sections and ASTM A578-07Bars ASTM E112-Rev C (2012)

ISO 7452:2002ASTM E208-06ASTM E381-01 (2006)ASTM A255-2010

Chapter 4 – Steel Castings ASTM G48-11ISO 1161: 1984/Amendment 1: 2007

Chapter 5 – Steel Forgings ASTM E112-12ASTM G48-11

Chapter 8 – Aluminium Alloys ASTM G66-99 (2005)e1ASTM G67-04

Chapter 9 – Copper Alloys ASTM E272-2010EN 1057: 2006 +A1: 2010

Chapter 10 – Equipment for ISO 1704: 2008Mooring and Anchoring ISO 1834: 1999

ISO 4565: 1986ASTM E112-2010ASTM E381-01 (2006)ASTM A255-2010

Chapter 11 – Approval of ISO 3690: 2000Welding Consumables ISO 10042: 2005

ASTM G48-11

Chapter 12 – Welding ISO 6947: 2011Qualifications ISO 5817: 2007

ISO 6520-1: 2007ISO 6507-1: 2005ISO 10042: 2005ASTM G48-11ISO 25239-3: 2011ISO 25239-4: 2011

Chapter 13 – Requirements ISO 9712/Cor1: 2006for Welded Construction ISO 6520-1: 2007

SNT TC-1A-2011AWS D3.6M:2010ISO 10042: 2005ISO 25239-5: 2011


5.4.2 The shipyard, fabricator or manufacturer may submitother Codes or Standards for consideration by LR, providingthey are equivalent to these Rules. Where no agreedacceptance standard is in place, the acceptance levelscontained in the subsequent Chapters of these Rules are toapply.

5.4.3 In the event that proposed acceptance criteria arenot considered to be equivalent to these Rules, the criteriamay be submitted for special consideration.

5.5 Non-destructive examination reports

5.5.1 NDE reports are to include all information requiredto identify how the examination was executed and are toinclude the following information where appropriate:(a) Date of test.(b) Name and qualification of operator with signatures of the

operator.(c) Details of the component identification, description of

test location and volume examined.(d) Heat treatment status.(e) Weld type, procedure and configuration.(f) Surface condition.(g) Test procedure.(h) Equipment used.(j) Test results with a map or record of reportable and/or

reject indications, giving location, dimensions andnature of indications.

(k) Reference to acceptance criteria and evaluation inaccordance to these criteria.

(l) Material type and thickness.(m) Calibration.

■ Section 6References

6.1 General

6.1.1 The locations of National and InternationalStandards referenced in these Rules are shown in Table 1.6.1.



LLOYD’S REGISTER8

Table 1.6.1 List of National and InternationalStandards (see continuation)

General RequirementsRULES FOR THE MANUFACTURE, TESTING AND CERTIFICATION OF MATERIALS, July 2014

Chapter 1Section 6


Table 1.6.1 List of National and InternationalStandards (conclusion)

Rule reference Standard

Chapter 14 – Plastics ISO 527-2: 2012Materials ISO 178: 2010

ISO 62: 2008ISO 75-2: 2004ISO 604: 2002ISO 527-4: 1997ISO 14125: 1998/ amd1:2011ISO 14130: 1997/ corr1:2003ISO 1172: 1996ISO 1922- 2012ASTM C273/C273M-11ASTM C393/C393M-11ISO 845- 2006ASTM C297/C297M-04ISO 844-2007ISO 1922-2001ISO 180-2000 ASTM D2583-07BS 2782-10 Method 1001: 1977ISO 175: 2010BS 1088-1: 2003BS 1088-2: 2003

1.2.2 Tensile testing machine load cells are to be calibrated with an accuracy of ± one per cent in accordancewith ISO 7500-1 or another recognised National Standard.

1.2.3 Impact tests are to be carried out on Charpy V-notch machines calibrated to ISO 148 or ASTM E23 dependent on the testing machine type. The testingmachines are to be calibrated using either a direct or indirectmethod. Other National Standards equivalent to ISO 148 maybe considered.

1.2.4 Hardness testing machines, together with theirassociated measuring microscopes, are to be directly andindirectly calibrated to ISO 6506-2, 6507-2 or equivalentstandards applicable to the type of hardness test. OtherNational Standards equivalent to ISO 6507-2 and 6506-2standards may be considered. Routine hardness checks withstandard hardness blocks calibrated to ISO 6506-3 or ISO 6507-3 or equivalent are to be carried out at a frequencywhich demonstrates calibration consistency.

1.3 Discarding of test specimens

1.3.1 If a test specimen fails because of faulty preparationor incorrect operation of the testing machine it may bediscarded and replaced by a new test specimen preparedfrom material adjacent to the original test.

1.3.2 In addition to the discarding of test specimens asindicated in 1.3.1, a tensile test specimen may also bediscarded when the specified minimum elongation is notobtained and the distance between the fracture and the nearest gauge mark is less than one-quarter of the gaugelength.

1.4 Re-testing procedures

1.4.1 Where the result of any test, other than an impacttest, does not comply with the requirements, two additionaltests of the same type are to be made from the same testsample, or if sufficient material is not available, a further representative sample taken from the item under test. Foracceptance of the material, satisfactory results are to beobtained from both of these additional tests.

1.4.2 Where the result of any test taken from a weldprocedure approval test, other than an impact test, does notcomply with the requirements, two additional tests of thesame type are to be made from the same weld test assembly.Where insufficient original welded assembly is available, a newassembly is to be prepared using the same conditions as theoriginal test weld. For acceptance, satisfactory results are tobe obtained from both of these additional tests.

Testing Procedures for Metallic Materials

Section

1 General requirements for testing

2 Tensile tests

3 Impact tests

4 Ductility tests for pipes and tubes

5 Embrittlement tests

6 Crack tip opening displacement tests

7 Bend tests

8 Hardness testing

9 Corrosion tests

■ Section 1General requirements for testing

1.1 Preparation of test specimens

1.1.1 The requirements specified below detail all thetests that may be applied to metallic materials. The specifictests and the test specimen types required for each materialtype, grade and product type are detailed in the subsequentChapter of these Rules.

1.1.2 Where test material is cut from products byshearing or flame cutting, a reasonable margin is required toallow sufficient material to be removed from the cut edgesduring machining of the test specimens.

1.1.3 Test specimens are to be prepared in such amanner that they are not subjected to any significant workhardening, cold straining or heating during straightening ormachining.

1.1.4 Test samples are not to be removed from the material they represent until heat treatment is complete. Forcastings in cases where test samples are separately cast, thecastings and samples are to be heat treated together.

1.1.5 Dimensional tolerances are to comply with a relevant ISO specification.

1.2 Testing machines

1.2.1 All tests are to be carried out by competent personnel. Testing machines are to be maintained in a satisfactory and accurate condition and are to be recalibratedat approximately annual intervals. This calibration is to becarried out by organisations of standing that have beenapproved or recognised by a National Authority and are to beto the satisfaction of the Surveyor. A record of all calibrationsis to be kept available in the test house.


Chapter 2Section 1



■ Section 2Tensile tests

2.1 Dimensions of test specimens

2.1.1 Proportional test specimens with a gauge length Lo of 5,65 or 5d, where So is the cross-sectional area, dthe diameter and Lc the parallel test length, have beenadopted as the standard form of test specimen, and in subsequent Chapters in these Rules the minimum percentageelongation values are given for test specimens of theseproportions.

2.1.2 The gauge length is to be greater than 20 mm andmay be rounded off to the nearest 5 mm provided that thedifference between the adjusted gauge length and the calculated one is less than 10 per cent of the calculatedgauge length.

2.1.3 For forgings and castings (excluding those in greycast iron) proportional test specimens of circular cross-section are to be machined to the dimensions shown inFig. 2.2.1.

2.1.4 For hot rolled bars and similar products, the testspecimens are to be as in Fig. 2.2.1, except that for smallsizes they may consist of a suitable length of bar or otherproduct tested in the full cross-section.

2.1.5 As an alternative to 2.1.3 and 2.1.4, proportional ornon-proportional test specimens of other dimensions may beused, subject to any requirements for minimum cross-sectional area given in subsequent Chapters of these Rules.Where the size of proportional test specimens is other thanas shown in Fig. 2.2.1, the general dimensions are to conformwith Fig. 2.2.2.

So

1.4.3 Where the result of any test taken from a weldingconsumable approval test, other than an impact test, doesnot comply with the requirements, two additional tests of thesame type are to be made from the same weld test assembly.Where insufficient original welded assembly is available, a newassembly is to be prepared using welding consumables fromthe same batch. If the new assembly is made with the sameprocedure (particularly the same number of runs) as the original assembly, only the duplicate re-test specimens needbe prepared and tested. For acceptance of a weld consumable batch, satisfactory results are to be obtainedfrom both of these additional tests.

1.4.4 Where the results from a set of three impact testspecimens do not comply with the requirements, an additional set of three impact test specimens may be testedprovided that, of the original set tested, not more than twoindividual values are less than the required average value and,of these, not more than one is less than 70 per cent of thisaverage value. The results obtained are to be combined withthe original results to form a new average which, for accep-tance, is to be not less than the required average value.Additionally, for these combined results, not more than twoindividual values are to be less than the required averagevalue and, of these, not more than one is to be less than 70 per cent of this average value.

1.4.5 The additional tests detailed in 1.4.1 and 1.4.2 are,where possible, to be made on material adjacent to the original samples. For castings, where insufficient materialremains in the original test samples, the additional test maybe made on other test samples representative of the castings.See also 1.3 for discarding of test specimens.

1.4.6 When unsatisfactory results are obtained from testsrepresentative of a batch of material, the item or piece fromwhich the tests were taken is to be rejected. The remainder ofthe material in the batch may be accepted provided that twofurther items or pieces are selected and tested with satisfactory results. If the tests from one or both or theseadditional items or pieces give unsatisfactory results, thebatch is to be rejected.

1.4.7 When a batch of material is rejected, the remainingitems or pieces in the batch may be resubmitted individuallyfor test, and those which give satisfactory results may beaccepted.

1.4.8 At the option of the manufacturer, rejected materialmay be resubmitted as another grade and may then beaccepted, provided that the test results comply with the appropriate requirements.

1.4.9 When material which is intended to be supplied inthe ‘as-rolled’ or ‘hot-finished’ condition fails test, it may besuitably heat treated and resubmitted for test. Similarly, materials supplied in the heat treated condition may be reheattreated and resubmitted for test. Unless otherwise agreed bythe Surveyor, such reheat treatment is to be limited to onerepeat of the final heat treatment cycle.



LLOYD’S REGISTER2

R ≥ 10 mm

Lo = 70 mm

Lc = approx. 77mm

d = 14 mm

NOTE: For nodular cast iron and materials with a specified elongation less than 10%, R ≥ 20 mm

Fig. 2.2.1Test specimen dimensions for forgings and

castings – I

2.1.7 As an alternative to 2.1.6, test specimens with awidth of other than 25 mm may be used subject to anyrequirements for minimum cross-sectional area given insubsequent Chapters of these Rules. A ratio of width/thickness of 8:1 should not be exceeded.

2.1.8 For pipes and tubes, the test specimens may consistof a suitable length tested in full cross-section with the endsplugged. The gauge length is to be 5,65 or 50 mm, andthe length of the test specimen between the grips or plugs,whichever is the smaller, is to be not less than the gauge lengthplus D, where D is the external diameter. Alternatively, testspecimens may be prepared from strips cut longitudinally andmachined to the dimensions shown in Fig. 2.2.5 or Fig. 2.2.6.The parallel test length is not to be flattened, but the enlargedends may be flattened for gripping in the testing machine.The cross-sectional area of this type of test specimen is to be calculated from:

So = ab

whereSo = cross-sectional areaa = average radial thicknessb = average width

Test specimens of circular cross-section may also be usedprovided that the wall thickness is sufficient to allow themachining of such specimens to the dimensions shown inFig. 2.2.1, with their axes located at the mid-wall thickness.

2.1.9 For wire, the test specimen may consist of a suitablelength tested in full cross-section. The gauge length is to be200 mm and the parallel test length 250 mm.

So


2.1.6 For plates, strip and sections, the test specimensare to be machined to the dimensions shown in Fig. 2.2.3 orFig. 2.2.4. Where the capacity of the available testing machineis insufficient to allow the use of a test specimen of full thickness, this may be reduced by machining one of the rolledsurfaces. Alternatively, for materials over 40 mm thick, testspecimens of circular cross-section machined to the dimensions shown in Fig. 2.2.1 may be used. The axes ofthese test specimens are to be located at approximately onequarter of the thickness from one of the rolled surfaces.


Chapter 2Section 2


NOTE: For nodular cast iron and materials with a specified elongation less than 10%, R ≥ 1,5d

R ≥ 10 mm

Lo = 5d

Lc = approx. Lo + d

d

Fig. 2.2.2Test specimen dimensions for forgings and

castings – II and aluminium alloys

R ≥ 25 mm

5,65 So

Approximately 7,65 So

a

a = thickness of material

So

25 mm

R ≥ 25 mm

200 mm

Approx. 212,5 mm

a

a = thickness of material

25 mm

Fig. 2.2.3Test specimen dimensions for plates, strip and

sections – I and aluminium alloys

Fig. 2.2.4Test specimen dimensions for plates, strip and

sections – II

R ≥ 10 mm

Approximately

5,65 So + 2b

a

b = 12 mm min.

So

5,65 So

a

R ≥ 10 mm

60 mm min.

a

b = 12 mm min.So

50 mm

a

Fig. 2.2.5Test specimen dimensions for pipes and tubes – I

Fig. 2.2.6Test specimen dimensions for pipes and tubes – II

2.1.14 Through-thickness tensile test specimens may be,at the option of the steelmaker, either plain test specimens ortest specimens with welded extensions in accordance with aRecognised Standard. The extension pieces are to be of steelwith a tensile strength exceeding that of the plate to be testedand may be attached to the plate surfaces by manual, resistance or friction welding carried out in such a way as toensure a minimal heat affected zone.

2.1.15 Tolerances on tensile specimen dimensions are tobe in accordance with ISO 6892-1 or another RecognisedStandard as appropriate.

2.2 Definition of yield stress for steel

2.2.1 The yield phenomenon is not exhibited by all thesteels detailed in these Rules but, except for austenitic andduplex stainless steels, the term ‘yield stress’ is used throughout when requirements are specified for acceptancetesting at ambient temperature. For the purposes of theRules, the terms ‘yield stress’ and ‘yield strength’ are to beregarded as synonymous.

2.1.10 For grey iron castings, the test specimens are to bemachined to the dimensions shown in Fig. 2.2.7 or Fig. 2.2.8.

2.1.11 For aluminium alloy plates and sections of thick-ness, a, less than or equal to 12,5 mm; the dimensions ofrectangular cross-sectioned test specimens are to be asshown in Fig. 2.2.3. The rectangular cross-sectioned testspecimen surfaces should remain as rolled/extruded. Wherethe thickness, a, is greater than 12,5 mm the test specimensare to be of round type as shown in Fig. 2.2.2.

2.1.12 Deposited weld metal tensile test specimens are tobe machined to the dimensions shown in Fig. 2.2.9, and maybe heated to a temperature not exceeding 250°C for a periodnot exceeding 16 hours for hydrogen removal, prior to testing.

2.1.13 Butt weld tensile test specimens are to bemachined to the dimensions shown in Fig. 2.2.10. For thicknesses of more than 2 mm, the test width is to be 25 mm. For thicknesses less than 2 mm, the test width is tobe reduced to 12 mm. The upper and lower surfaces of theweld are to be filed, ground or machined flush with thesurface of the plate.

Gauge length 50 mmR ≥ 10 mm

10 mm

Parallel length 55 mm

To s

uit g

rips

12 m

m m

in.

Testing Procedures for Metallic MaterialsRULES FOR THE MANUFACTURE, TESTING AND CERTIFICATION OF MATERIALS, July 2014

Chapter 2Section 2

LLOYD’S REGISTER4

Fig. 2.2.9Test specimen for deposited weld metal tensile

R ≥ 25 mm

Lc ≥ 55 mm (parallel)

d = 20 mm

Fig. 2.2.8Test specimen dimensions for grey iron castings – II

25 m

m

Parallel test length= width of weld +

60 mm

Wid

th to

suit

grip

s

R ≥ 25 mm

Fig. 2.2.10 Test specimen for butt weld

R ≥ 25 mm

d = 20 mm

Fig. 2.2.7Test specimen dimensions for grey iron castings – I

2.4 Equivalent elongations

2.4.1 When a gauge length other than 5,65 is used,the equivalent percentage elongation value is to be calculatedusing the following formula:

A =0,40( )

whereAR = actual measured percentage elongation of test

specimenSo = actual cross-sectional area of test specimenLo = actual gauge length of test pieceA = equivalent percentage elongation for a test specimen

with a gauge length of 5,65 .

2.4.2 Alternatively, where a number of test specimens ofsimilar material and dimensions are involved, the actualpercentage elongation values may be recorded, provided thatthe equivalent specified minimum elongation value appropriatefor the test specimen dimensions is calculated from theformula in 2.4.1 and is recorded on the test certificate.

2.4.3 For proportional test specimens having a gaugelength other than 5,65 , the equivalent elongation maybe calculated using the following factors (d is the diameter ofthe test specimen):

Actual gauge Factor for equivalentlength elongation on 5,654 x 0,870

8,16 x 1,158

11,3 x 1,317

4d x 0,916

8d x 1,207

2.4.4 For non-proportional test specimens with gaugelengths of 50 mm and 200 mm, the equivalent elongationvalues tabulated in ISO 2566 are to apply.

2.4.5 The above conversions are reliable only for carbon,carbon-manganese and low alloy steels with a tensile strengthnot exceeding 700 N/mm2 in the hot rolled, annealed,normalised, or normalised and tempered condition.

2.4.6 For alloy steels in the quenched and temperedcondition, the following conversions may be used for propor-tional test specimens with a gauge length of 4 :

Actual percentage Equivalent elongationelongation on 4 on 5,65

22 1720 1518 1317 1216 1215 1114 1012 810 78 5

So So

So

So

So

So

So

So

So

So

AR

2

Lo

So


2.2.2 Where reference is made to ‘yield stress’ in therequirements for carbon, carbon-manganese and alloy steelproducts and in the requirements for the approval of weldingconsumables, either the upper yield stress or, where this is notclearly exhibited, the 0,2 per cent proof stress or the 0,5 percent proof stress under load is to be determined. In cases ofdispute, the 0,2 per cent proof stress is to be determined.

2.2.3 For austenitic and duplex stainless steel productsand welding consumables, both the 0,2 and the 1,0 per centproof stresses are to be determined.

2.3 Procedure for testing at ambient temperature

2.3.1 Except as provided in 2.3.5, the elastic stress ratefor the determination of the upper yield for steels and copperalloys is to be between 6 and 60 N/mm2 per second andbetween 2 and 20 N/mm2 per second for aluminium. Afterreaching the yield or proof load, the straining rate may beincreased to a maximum of 0,008s–1 for the determination ofthe tensile strength.

2.3.2 For steel, the upper yield stress is to be calculatedfrom:(a) the value of stress measured at the commencement of

plastic deformation, or(b) on a load/extension diagram using the value of stress

measured at the first peak obtained during yielding evenwhen the peak is equal to or less than any subsequentpeaks observed during plastic deformation at yield.

2.3.3 When a well defined yield point cannot be obtained,the 0,2 or 1,0 per cent proof stress (non-proportional elongation) is to be determined from an accurate load/extension diagram by drawing a line parallel to the straightelastic portion and a distance from it where the amount represents 0,2 or 1,0 per cent of the extensometer gaugelength. The point of intersection of this line with the plasticportion of the diagram represents the proof load, from whichthe 0,2 or 1,0 per cent proof stress can be calculated.

2.3.4 For stainless steels, the 1,0 per cent proof stressand/or 0,2 per cent proof stress is specified as required bythe relevant Chapters in these Rules.

2.3.5 For the determination of the tensile strength of flakegraphite cast iron, the stress rate is not to exceed 10 N/mm2

per second.

2.3.6 A measured elongation value is to be regarded asvalid only if the fracture occurs within the gauge length and atleast the following distances from the gauge marks:

Round test specimen: 1,25dFlat test specimen: a plus width of specimen

The measurement is valid irrespective of the position of the fracture, if the percentage elongation after fracture reaches atleast the specified value, and this is to be stated in the testreport.


Chapter 2Section 2


2.4.7 Any proposals to use conversion factors for equiva-lent elongation values for the following materials are to beagreed with the Surveyors:(a) Carbon, carbon-manganese and alloy steels in the

normalised or normalised and tempered condition with atensile strength exceeding 700 N/mm2.

(b) Cold-worked steels.(c) Austenitic stainless steels.(d) Non-ferrous alloys.

2.5 Procedure for testing at elevatedtemperatures

2.5.1 The test specimens used for the determination oflower yield or 0,2 per cent proof stress at elevated tempera-tures are to have an extensometer gauge length of not lessthan 50 mm and a cross-sectional area of not less than65 mm2. Where, however, this is precluded by the dimensionsof the product or by the test equipment available, the testspecimen is to be of the largest practicable dimensions.

2.5.2 The heating apparatus is to be such that thetemperature of the specimen during testing does not deviatefrom that specified by more than ±5°C.

2.5.3 The straining rate when approaching the lower yieldor proof load is to be controlled within the range 0,1 to 0,3 per cent of the extensometer gauge length per minute.

2.5.4 The time intervals used for estimation of strain ratefrom measurements of strain are not to exceed 6 seconds.

■ Section 3Impact tests


3.1.1 Impact tests are to be of the Charpy V-notch type.The test specimens are to be machined to the dimensionsand tolerances given in Table 2.3.1 and are to be carefullychecked for dimensional accuracy.

3.1.2 For material under 10 mm in thickness, the largestpossible size of standard subsidiary Charpy V-notch testspecimen is to be prepared with the notch cut on the narrowface. Generally, impact tests are not required when the thickness of the material is less than 6 mm.

3.2 Testing procedures

3.2.1 All impact tests are to be carried out on Charpymachines approved by Lloyd’s Register (hereinafter referredas LR) and having a striking energy of not less than 150 J.


3.2.2 Charpy V-notch impact tests may be carried out atambient or lower temperatures in accordance with the specificrequirements given in subsequent Chapters of these Rules.Where the test temperature is other than ambient, the tempera-ture of the test specimen is to be controlled to within ±2°C forsufficient time to ensure uniformity throughout the cross-sectionof the test specimen, and suitable precautions are to be takento prevent any significant change in temperature during the actualtest. In cases of dispute, ambient temperature is to be considered as 18°C to 25°C.

3.2.3 For acceptance, the average energy value for a setof three impact tests must be equal to or greater than theappropriate specified minimum average value. Additionally,only one individual value may be less than the required average value but not less than 70 per cent of this averagevalue.

3.2.4 Where standard subsidiary Charpy V-notch testspecimens are necessary, the minimum energy valuesrequired are to be reduced as follows:

Specimen 10 x 7,5 mm: 5/6 of tabulated energy.Specimen 10 x 5 mm: 2/3 of tabulated energy.

3.2.5 When reporting results, the specimen dimensionsand the units used for expressing the energy absorbed(Joules) and the testing temperature are to be clearly stated.



LLOYD’S REGISTER6

Dimension Nominal Tolerance

Length, in mm 55 ±0,60Height, in mm, see Note 1 10 ±0,075Width, in mm, see Note 1

– standard specimen 10 ±0,11– standard subsidiary

specimen 7,5 ±0,11– standard subsidiary

specimen 5 ±0,06Angle of notch 45° ±2°Height below notch, in mm 8 ±0,075Root radius, in mm 0,25 ±0,025

Distance of plane of symmetry ofnotch from ends of test piece, in mm,see Note 1 27,5 ±0,42,

see Note 2Angle between plane of symmetry of

notch and longitudinal axis of testpiece 90° ±2°

Angle between adjacent longitudinal faces of test piece 90° ±2°

NOTES1. The test piece is to have a surface roughness better than Ra 5

µm except for the ends.2. For machines with automatic positioning of the test piece the

tolerance is to be taken as ±0,165 mm.

Table 2.3.1 Dimensions and tolerances for CharpyV-notch impact test specimens

Width

Height


■ Section 4Ductility tests for pipes and tubes

4.1 Bend tests

4.1.1 The test specimens are to be cut as circumferentialstrips of full wall thickness and with a width of not less than40 mm. For thick walled pipes, the thickness of the test specimens may be reduced to 20 mm by machining. Theedges of the specimens may be rounded to a radius of 1,6 mm.

4.1.2 Testing is to be carried out at ambient temperature,and the specimens are to be doubled over a former whosediameter is to be in accordance with the specific requirementsfor the material. For submerged arc welded tube the testpiece is to be bent with the root of the weld in tension. Forother tubes, the test piece is to be bent in the original direction of curvature. In all cases, the welds are to be in themiddle of the test specimen. The test is considered to besatisfactory if, after bending, the specimens are free fromcracks and laminations. Small cracks at the edges of the testspecimens are to be disregarded.

4.2 Flattening tests

4.2.1 Ring test specimens are to be cut with the endsperpendicular to the axis of the pipe or tube. The length of thespecimen is to be equal to 1,5 times the external diameter ofthe pipe or tube, but is to be not less than 10 mm or greaterthan 100 mm. Alternatively, the length of the test specimenmay be 40 mm irrespective of the external diameter.

4.2.2 Testing is to be carried out at ambient temperatureand is to consist of flattening the specimens in a directionperpendicular to the longitudinal axis of the pipe. Flattening isto be carried out between two plain parallel and rigid platenswhich extend over both the full length and the width after flattening of the test specimen. Flattening is to be continueduntil the distance between the platens, measured under load,is not greater than the value given by the formula:

H =

whereH = distance between plates, in mmt = specified thickness of the pipe, in mm

D = specified outside diameter, in mmC = a constant dependent on the steel type and

detailed in the specific requirementsAfter flattening, the specimens are to be free from cracks orother flaws. Small cracks at the ends of the test specimensmay be disregarded.

4.2.3 For welded pipes or tubes, the weld is to be placedat 90° to the direction of flattening.

4.3 Drift expanding tests

4.3.1 The test specimens are to be cut with the endsperpendicular to the axis of the tube. The edges of the endto be tested may be rounded by filing.

t (1 + C) t C +D

4.3.2 For metallic tubes, the length of the specimen is tobe at least 1,5 times the external diameter of the tube exceptwhen a mandrel with an included angle of 30° is used, inwhich case the length of the specimen is to be twice theexternal diameter of the tube. In all cases the length of sectionremaining cylindrical after test is not be less than 0,5 timesthe external diameter.

4.3.3 Testing is to be carried out at ambient temperatureand is to consist of expanding the end of the tube symmetrically by means of a hardened conical steel mandrelhaving a total included angle of 30°, 45° or 60°, see Fig. 2.4.1.The mandrel is to be forced into the test specimen at a ratenot exceeding 50 mm/min until the percentage increase in theoutside diameter of the end of the test specimen is not lessthan the value given in the specific requirements for boiler andsuperheater tubes, see Chapter 6. The mandrel is to be lubricated, but there is to be no rotation of the tube or mandrelduring the test. The expanded portion of the tube is to be freefrom cracks or other flaws.

4.4 Flanging tests

4.4.1 The test specimens are to be cut with the endsperpendicular to the axis of the tube. The length of the specimens is to be at least equal to the external diameter ofthe tube and such that after testing the portion that remainscylindrical is not less than half the external diameter. Theedges of the end to be tested may be rounded by filing.

4.4.2 Testing is to be carried out at ambient temperatureand is to consist of flanging the end of the tube symmetricallyby means of hardened conical steel mandrels. The rate offlanging is not to exceed 50 mm/min.


Chapter 2Section 4


30°, 45° or 60°

Fig. 2.4.1 Drift expanding test


4.4.3 The first stage of flanging is to be carried out with aconical angled mandrel having an included angle of approxi-mately 90°, see Fig. 2.4.2(a). The completion of the test isachieved with a second forming tool as shown in Fig. 2.4.2(b).The mandrels are to be lubricated and there is to be no rotation of the tube or mandrels during the test. The test is tocontinue until the drifted portion has formed a flange perpendicular to the axis of the test specimens. The percentageincrease in the external diameter of the end of the specimensis to be not less than the value given in the specific require-ments for boiler and superheater tubes, see Chapter 6. Thecylindrical and flanged portion of the tube is to be free fromcracks or other flaws.

■ Section 5Embrittlement tests

5.1 Temper embrittlement tests

5.1.1 The test material is to be heat treated in accordancewith the specification except that after tempering:(a) half the material is to be water quenched;(b) the other half is to be cooled from the tempering temper-

ature to 300°C at a rate not exceeding 10°C per minute.

5.1.2 Impact tests in accordance with Section 3 are tobe made on the material in each condition at temperaturesover a range wide enough to establish the upper and lowershelf energies and temperatures, tests being made at no lessthan three intermediate temperatures.

5.1.3 A set of three specimens is to be tested at eachtemperature. The results are to be plotted separately for eachcondition, in the form illustrated in Fig. 2.5.1. In addition, thetest temperatures, proportions of crystallinity and absorbedenergies for all the specimens tested are to be reported.

5.1.4 The transition temperature for each condition is tobe taken as the mid-temperature of the fracture transitionzone. The difference between the two transition temperaturesis to be reported.

5.2 Strain age embrittlement tests

5.2.1 The test material is to be heat treated in accordancewith the specification and then subjected to five per centstrain. Half of the test material is then to be heated to 250°Cand held for one hour.

5.2.2 Impact tests in accordance with 5.1.2 are to bemade in both the strained and unstrained conditions.

5.2.3 The tests are to comply with 5.1.3.

5.2.4 The test results are treated in accordance with5.1.4.

5.3 Hydrogen embrittlement tests

5.3.1 Two specimens are to be tested. The specimensare to be of a diameter of 20 mm. Where this is notpracticable a diameter of 14 mm may be accepted.

5.3.2 One specimen is to be tested within a maximum of3 hours after machining. Where the specimen diameter is 14 mm, the time limit is 1,5 hours. Alternatively, the specimenmay be cooled to –60°C immediately after machining andkept at that temperature for a maximum period of 5 daysbefore being tested.

5.3.3 The other specimen is to be tested after baking at250°C for 4 hours. Where the specimen diameter is 14 mmthe baking time is to be 2 hours.



LLOYD’S REGISTER8

Upper-shelftoughness

Ductile fracture(Fibrous shear)

Ductile zoneFracture transition

zone

Mixedductile and

brittle fracture

Temperature

Brittlefracture

(Cleavage)

Ene

rgy

abso

rbed

in fr

actu

re (t

ough

ness

)

Brittle zone

Fig. 2.5.1 Idealised transition curve

90°

(a) (b)

Fig. 2.4.2 Flanging test

6.2 Test equipment

6.2.1 Whenever possible, tests are to be made usingmachines operating under displacement control. The type ofcontrol is to be recorded.

6.2.2 The test equipment is to be calibrated annually.

6.2.3 The crack opening displacement gauge is to havean accuracy of at least one per cent. It is to be calibrated atleast once every day of testing and at intervals of no morethan 10 tests. It should be demonstrated that the calibrationis satisfactory for the test conditions.


6.3.1 Tests are to be made in a recognised test house inaccordance with a nationally accepted standard.

6.3.2 Unless otherwise agreed, all tests on unweldedwrought material are to be made on specimens taken transverse to the principal working direction and are to bethrough-thickness notched.

6.3.3 Where tests are made on weld material, the fatiguecrack should be arranged to sample the maximum amount ofunrefined weld metal.

6.3.4 Where tests are made on the Heat Affected Zone(H.A.Z.) of a weld, a K or single bevel weld preparation isrecommended. The region of lowest fracture toughness in theHeat Affected Zone should be identified for the particular steeland weld procedure by means of preliminary tests. Thefatigue crack is to be accurately positioned to sample as higha proportion of this critical region as possible and after testinghas been completed, the specimen is to be sectioned tocheck that this has been achieved. Sufficient tests should bemade to ensure that the critical region has been sampled in atleast three specimens.

6.3.5 At least three valid tests are to be made for eachmaterial condition. Invalid tests are to be disregarded and thetests repeated.


5.3.4 A strain rate not exceeding 0,0003s–1 is to be usedduring the entire test, until fracture occurs.

5.3.5 Tensile strength, elongation and reduction of areaare to be reported.

5.3.6 The ratio Z1/Z2 is to be reported, where Z1 is thereduction in area without baking and Z2 the reduction in areaafter baking.

■ Section 6Crack tip opening displacementtests


6.1.1 Unless agreed otherwise, tests are to be made onspecimens of the full section thickness and which conform toa nationally agreed standard.

6.1.2 Normally the specimens are to be rectangular withthe main dimensions as indicated in Fig. 2.6.1 and are to betested in three point bending.

6.1.3 A subsidiary specimen as in Fig. 2.6.2 may be usedby agreement.

6.1.4 In each case the notch is to be positioned at thecentre of the loading span; its root radius is not to exceed0,10 mm. The notch is to be extended by the generation of afatigue crack to give an effective crack length of the dimension a. For this purpose, the fatigue stress ratio, R1, isto be within the range 0 to 0,1 and the fatigue intensity is notto exceed 0,63σγ B1/2 where σγ is the 0,2 per cent proofstress at the test temperature.




L

a

2,1W min. 2,1W min.

W

B

B = thickness

W = width = 2B

a = effective crack length = 0,45W to 0,55W

L = loading span = 4W

Fig. 2.6.1Outline dimensions of the preferred specimen

L

a

2,3W 2,3W

W

B

B = thicknessW = width = Ba = effective crack length (to be agreed between the purchaser and manufacturer)L = loading span = 4W

Fig. 2.6.2Outline dimensions of the subsidiary specimen

■ Section 7Bend tests


7.1.1 Flat bend test specimens are to be of rectangularcross-section with dimensions as defined in Fig. 2.7.1.

7.1.2 For plates, sections and strip the dimensions shallbe full thickness and width 30 mm. Where the rolled thickness exceeds 25 mm the compression face may bereduced to 25 mm.

7.1.3 For forgings, castings and semi-finished productsthe thickness shall be 20 mm and width 25 mm.

7.1.4 Butt weld face and root bend test specimens areto be 30 mm in width and of the full plate thickness. Wherethe thickness exceeds 25 mm, two side bend test specimensmay be tested in place of the face and root specimens specified. The side bend specimens should be 10 mm minimum thickness. The upper and lower surfaces of the weldare to be filed, ground or machined flush with the surface ofthe plate.

7.1.5 The edges on the tension side of bend samples areto be rounded to a radius of 1 to 2 mm.


7.2.1 The bend sample is plastically deformed by plunginga mandrel between two fixed points as shown in Fig. 2.7.2.

7.2.2 For aluminium welds a guided bend is required toensure even deformation as shown in Fig. 2.7.3.

7.2.3 Bend tests are to be conducted at ambient temper-ature at the highest convenient rate of bending (but notimpact).

6.3.6 Local pre-compression of the test specimen aheadof the notch is acceptable in order to provide an acceptablyeven fatigue crack front.

6.3.7 The temperature of the test piece is to be measuredto within ±2°C over the range minus 196°C to +200°C and towithin ±5°C outside this range. The temperature should bemeasured at a point on the specimen not farther than 2 mmaway from the crack tip.

6.4 Validity requirements

6.4.1 The test is to be regarded as invalid if:(a) the fatigue crack front is not in a single plane;(b) any part of the fatigue crack surface lies in a plane

whose angle with the plane of the notch exceeds 10°;(c) the length of any part of the fatigue crack is less than

0,025W or 1,25 mm, whichever is the greater;(d) the difference between the maximum and minimum

lengths of the fatigue crack exceeds 0,1W;(e) the difference between any two of the lengths of the

fatigue crack at 0,25B, 0,5B and 0,75B exceeds 0,05W.

6.4.2 In addition, for tests on welds and Heat AffectedZones (H.A.Z.), the following criteria are to be complied with:(a) Weld metal. The fatigue crack front shall not extend

outside the weld metal deposit and 80 per cent shouldbe within 2 mm of the fusion line.

(b) Grain coarsened H.A.Z.. The fatigue crack should bewithin 0,5 mm of the fusion line and should sample all ofthe grain coarsened H.A.Z. present. However, if fusionline irregularities prevent this, a sample including as muchgrain coarsened H.A.Z. as possible may be accepted.

(c) Subcritical/intercritical H.A.Z. boundary. The fatigue crackis to sample the boundary between the subcritical andintercritical regions of the H.A.Z. However, if fusion lineirregularities prevent this, a sample including as muchrelevant microstructure as possible may be accepted.

6.5 Test reports

6.5.1 The test report is to include:(a) details of the material, its condition and size;(b) the thickness and width of the test specimen;(c) the fatigue pre-cracking conditions;(d) the test temperature and environment;(e) the test machine control system and rate of change of

displacement or load;(f) crack length measurements;(g) force/displacement records, preferably in the form of an

autographic record;(h) the critical crack opening displacement;(j) a photograph of the fracture;(k) any observation on the fracture surface.




D

a

(11a) or (9a + D)1-2 mm 1-2 mm

b

Fig. 2.7.1 Bend test specimen

■ Section 8Hardness testing


8.1.1 Test pieces must be held rigidly in relation to theindenter and located such that the surface to be tested is atright angles to the axis of the indenter.

8.1.2 The surface finish of the test piece is to be such asto be able to measure the indent accurately.

8.2 Testing procedure

8.2.1 Hardness testing is to be carried out according toISO 6506-1, ISO 6507-1 or equivalent for the type ofhardness test.

■ Section 9Corrosion tests

9.1 Intergranular corrosion test

9.1.1 For all products other than pipes, the material forthe test specimens is to be taken adjacent to that for thetensile test and is to be machined to suitable dimensions foreither a round or rectangular section bend test. The diameteror thickness is to be not more than 12 mm, and the totalsurface area is to be between 1500 mm2 and 3500 mm2.

9.1.2 For pipes with an outside diameter not exceeding40 mm, the test specimens are to consist of a full cross-section. For larger pipes, the test specimens are to be cut ascircumferential strips of full wall thickness and having a widthof not less than 12,5 mm. In both cases the total surface areais to be between 1500 mm2 and 3500 mm2.

9.1.3 Specimens are to be heated to a temperature of700 ± 10ºC for 30 minutes, followed by rapid cooling in water.They are then to be placed on a bed of copper turnings (50 gper litre of test solution) and immersed for 15 to 24 hours in aboiling solution of the following composition:• 100 g of hydrated copper sulphate granules (CuSO4.

5H2O)• 184 g (100 ml) sulphuric acid (density 1,84 g/ml) added

dropwise to distilled water to make 1 litre of solution.Precautions are to be taken during boiling to prevent concentration of the solution by evaporation.

9.1.4 After immersion, the full cross-section test specimens from pipes are to be subjected to a flattening testin accordance with Ch 2,4.2. All other test specimens are tobe bent, at ambient temperature, through 90º over a formerwith a diameter equal to twice the diameter or thickness ofthe test specimen.

9.1.5 After flattening or bending, the test specimens areto be free from cracks on the outer, convex surface.


a = thickness of bend sampleR = radius of rollerD = outside diameter of former

D

a

R R

D + 3a

Fig. 2.7.2 Bend test

D

1,5 mmR

a

R

D a = plate ticknessD = mandrel diameterR = former radius

Fig. 2.7.3 Guide bend test for aluminium


Chapter 2Sections 7, 8 & 9

1.1.6 Steels intended for high heat input welding above50 kJ/cm are to be specially approved. Approval will be indicated on the manufacturer’s approval certificate by addinga high heat input welding notation to the grade approved, e.g.,EH36-W300, indicating approval up to 300 kJ/cm.

1.2 Steel with guaranteed through thicknessproperties – ‘Z’ grade steel

1.2.1 When plate material, intended for welded construction,will be subject to significant strains in a direction perpendicularto the rolled surfaces, it is recommended that consideration begiven to the use of special plate material with specified throughthickness properties, ‘Z’ grade steel. These strains are usuallyassociated with thermal contraction and restraint during welding, particularly for full penetration ‘T’-butt welds, but mayalso be associated with loads applied in service or duringconstruction. Where these strains are of sufficient magnitude,lamellar tearing may occur. Requirements for ‘Z’ grade platematerial are detailed in Section 8. It is the responsibility of thefabricator to make provision for the use of this material.

1.2.2 Steels intended to have guaranteed through thickness properties will include the supplementary suffix Z25or Z35 in the designation, for example: LR DH36 Z35.

1.3 Corrosion resistant steels for cargo oil tanksof crude oil tankers

1.3.1 This sub-Section refers to normal and higherstrength steels that have approved enhanced corrosion resistance properties intended for application in the internalcargo oil tanks of crude oil tankers.

1.3.2 The additional approval procedures for these steelsinclude specific corrosion tests, see Ch 1,2.2.

1.3.3 Normal and higher strength corrosion resistantsteels are to be manufactured, tested and certified in accor-dance with the applicable requirements of Section 2 orSection 3 and the requirements detailed in this sub-Section.

1.3.4 Corrosion resistant steels for cargo oil tanks areprimarily intended to apply to steel plates, wide flats andsections up to 50 mm thick and to bars up to 50 mm in diameter.

1.3.5 Corrosion resistant steels for cargo oil tanks are tobe identified with one of the following supplementary suffixes,RCU, RCB or RCW in the designation, for example, LR DH36RCB. These suffixes relate to the area of the tank for whichapproval testing has been obtained:

RCU, for lower surface of strength deck and surroundingstructures;RCB, for upper surface of inner bottom plating andsurrounding structures; RCW, for both strength deck and inner bottom plating.

1.3.6 Corrosion resistant steels are not to be used inapplications other than those specified in 1.3.1.

Rolled Steel Plates, Strip, Sections and Bars

Section

1 General requirements

2 Normal strength steels for ship and other structural applications

3 Higher strength steels for ship and other structural applications

4 Steels for boilers and pressure vessels

5 Steels for machinery fabrications

6 Ferritic steels for low temperature service

7 Austenitic and duplex stainless steels

8 Plates with specified through thickness properties

9 Bars for welded chain cables

10 High strength quenched and tempered steelsfor welded structures

■ Section 1General requirements

1.1 Scope

1.1.1 This Section gives the general requirements for hotrolled plates and sections intended for use in the constructionof ships, other marine structures, machinery, boilers and pressure vessels.

1.1.2 This Chapter is not applicable to hot rolled barsintended for the manufacture of bolts, plain shafts, etc., bymachining operations only. Where used for this purpose, hotrolled bars are to comply with the requirements of Chapter 5.

1.1.3 Plate and strip which is hot coiled after rolling andsubsequently uncoiled, cold flattened and cut to the requireddimensions are also subject to the appropriate requirementsof this Chapter.

1.1.4 Plates, strip, sections and bars are to be manufac-tured and tested in accordance with the requirements ofChapters 1 and 2, the general requirements of this Sectionand the appropriate specific requirements given in Sections 2to 10.

1.1.5 As an alternative to 1.1.4, materials which complywith National or proprietary specifications may be accepted,provided that these specifications give equivalence to therequirements of this Chapter or are approved for a specificapplication. Particular attention is to be taken of the minimumrequired under thickness tolerance, see 1.6. Generally, surveyand certification of such materials are to be carried out inaccordance with the requirements of Chapter 1.


Chapter 3Section 1



1.3.7 The weldability of corrosion resistant steels is similar to conventional normal and higher strength steels.Therefore the welding requirements specified in Chapters 11to 13 are to be adhered with the exception that each corrosion resistant steel is approved with a specified brand ofwelding consumable and associated welding process.

1.3.8 Each manufacturer’s approval certificate for corrosion resistant steels will state the steel grade and areaof application designation, specified chemical compositionrange including additive and/or controlling element percent-ages to improve corrosion resistance, and brand of weldingconsumables and welding process used for approval.

1.4 Manufacture

1.4.1 All materials are to be manufactured at works whichhave been approved by Lloyd’s Register (hereinafter referredto as ‘LR’) for the type and grade of steel which is beingsupplied and for the relevant steel-making and processingroute.

1.4.2 Steel is to be cast in metal ingot moulds or by thecontinuous casting process. The size of the ingot, billet or slabis to be proportional to the dimensions of the final productsuch that the reduction ratio is normally to be at least 3 to 1.Sufficient discard is to be taken to ensure soundness in theportion used for further processing.

1.4.3 The cast analysis to be used for certificationpurposes is to be determined after all alloying additions havebeen carried out and sufficient time allowed for such an addition to homogenise.

1.4.4 Material may be supplied either as-rolled, normalised,normalising rolled, or thermomechanically controlled rolled.The following definitions apply:(a) As-rolled (AR) refers to rolling of steel at high tempera-

ture followed by air cooling. The rolling and finishingtemperatures are typically in the austenite recrystallisa-tion region and above the normalising temperature. Thestrength and toughness properties of steel produced bythis process are generally less than those of steel heattreated, after rolling, or steel produced by advancedprocesses.

(b) Normalising (N) refers to an additional heating cycle ofrolled steel above the critical temperature, Ac3, and inthe lower end of the austenite recrystallisation regionfollowed by air cooling. The process improves themechanical properties of as-rolled steel by refining thegrain size.

(c) Normalising rolling (NR), also known as controlled rolling,is a rolling procedure in which the final deformation iscarried out in the normalising temperature range, resultingin a material condition generally equivalent to thatobtained by normalising.

(d) Thermomechanically controlled rolling (TM) is a procedurewhich involves the strict control of both the steel temper-ature and the rolling reduction. Generally a highproportion of the rolling reduction is carried out close tothe Ar3 temperature and may involve the rolling in the dualphase temperature region. Unlike normalising rolling theproperties conferred by TM (TMCP) cannot be repro-

duced by subsequent normalising or other heat treat-ment. The use of accelerated cooling on completion ofTM may also be accepted subject to the special approvalby LR.

(e) Accelerated Cooling, (AcC) is a process which aims toimprove mechanical properties by controlled cooling withrates higher than air cooling immediately after the final TMoperation. Direct quenching is excluded from acceleratedcooling. The material properties conferred by TM andAcC cannot be reproduced by subsequent normalisingor other austenitising heat treatment.

(f) Quenching and Tempering (QT),is a heat treatmentprocess in which steel is heated to an appropriatetemperature above the Ac3 and then cooled with anappropriate coolant for the purpose of hardening themicrostructure, followed by tempering, a process inwhich the steel is re-heated to an appropriate tempera-ture, not higher than the Ac1 to restore the toughnessproperties by improving the microstructure.

1.4.5 Where material is being produced by a normalisingrolling or a thermomechanically controlled process (T.M.) anadditional program of tests for approval is to be carried outunder the supervision of the Surveyors and the results are tobe to the satisfaction of LR.

1.4.6 Weldable high strength steels may be supplied inthe quenched and tempered condition for other marine structures, see Section 10.

1.5 Quality of materials

1.5.1 Surface and internal imperfections not prejudicial tothe proper application of the steel are not, except by specialagreement, to be grounds for rejection. Where necessary,suitable methods of non-destructive examination may beused for the detection of harmful surface and internal defects.The extent of this examination, together with an appropriateacceptance standard, is to be agreed between the purchaser,steelmaker and Surveyor and is to be included in the manufacturing specification.

1.6 Dimensional tolerances

1.6.1 The tolerances on thickness of a given product aredefined as:(a) Minus tolerance is the lower limit of the acceptable range

below the nominal thickness.(b) Plus tolerance is the upper limit of the acceptable range

above the nominal thickness.Nominal thickness is defined by the purchaser at the time ofenquiry and order.

1.6.2 The average thickness of a product or products isdefined as the arithmetic mean of the measurements madein accordance with the requirements in 1.6.11.


Chapter 3Section 1

LLOYD’S REGISTER2

1.6.3 For materials of nominal thickness 5 mm and moreintended for hull structural purposes as detailed in Sections 2, 3 and 10, the minus tolerance on thickness ofplates, strip and wide flats is 0,3 mm, irrespective of nominalthickness. For wide flats, this applies only where the width isgreater than or equal to 600 mm. The average thickness of aproduct or products is not to be less than the nominal thickness. For thicknesses below 5 mm, the thickness tolerances are to be specially agreed. Plus tolerance is to bein accordance with a National or International Standard.

1.6.4 Class C of ISO 7452 may be applied in lieu of 1.6.3.Where this standard is applied, both the requirements in1.6.11 and the portion of the footnote of Table B.2 in ISO 7542, that reads; ‘Also a minus side of thickness of 0,3 mm is permitted,’ are not applicable. Additionally, if ISO 7452 is applied, the steel mill is to ensure that the numberof measurements and measurement distribution is appropriateto establish that the plates produced are greater than or equalto the specified nominal thickness.

1.6.5 The minus tolerance on bars and sections (exceptfor wide flats with a width > 600 mm) is to be in accordancewith the requirements of a recognised National or InternationalStandard.

1.6.6 The Shipbuilder and Owner may agree in individualcases whether they wish to specify a more stringent minustolerance than that given in this Chapter.

1.6.7 The minus tolerances for plates and wide flatsintended for machinery structures are given in Section 5.

1.6.8 For materials intended for applications as detailedin Sections 4 and 6, no minus tolerance is permitted in thethickness of plates and strip. The minus tolerances onsections are to comply with the requirements of a recognisedNational or International Standard.

1.6.9 For the materials detailed in Section 7, the minustolerance of material intended for use in the construction ofcargo tanks is not to exceed 0,3 mm. For other applications,no minus tolerance is permitted in the thickness of plates andstrip.

1.6.10 Dimensional tolerances for material detailed inSection 9 are given in Table 3.9.3.

1.6.11 The average thickness and thickness tolerance isto be measured at locations of a product or products asdefined below:(a) An automated method or manual method may be

applied to the thickness measurements. The procedureand the records of measurements are to be made available to the Surveyor and copies provided onrequest.

(b) At least two lines among Line 1, Line 2 or Line 3, asshown in Fig. 3.1.1, are to be selected for the thicknessmeasurements and at least three points on eachselected line as shown in Fig. 3.1.1 are to be selectedfor thickness measurement on each piece rolled from asingle slab or ingot. If more than three points are takenon each line, then the number of points shall be equalon each line.

(c) For automated methods, the measuring points at sidesare to be located not less than 10 mm but not greaterthan 300 mm from the transverse or longitudinal edgesof the product.

(d) For manual methods, the measuring points at sides areto be located not less than 10 mm but not greater than100 mm from the transverse or longitudinal edges of theproduct.

(e) Additional measurements may be requested by theSurveyor.

1.6.12 Local surface depressions resulting from imperfec-tions and ground areas resulting from the elimination ofdefects may be disregarded provided that they are in accordance with the requirements of a recognised Nationalor International Standard.

1.6.13 Tolerances relating to length, width, flatness andplus thickness are to comply with a National or InternationalStandard.

1.6.14 The responsibility for maintaining the required tolerances and making the necessary measurements restswith the manufacturer. Occasional checking by the Surveyordoes not absolve the manufacturer from this responsibility.

1.6.15 The Shipbuilder is responsible for the storage andmaintenance of product(s) delivered with acceptable surfaceconditions.

1.7 Heat treatment

1.7.1 Acceptable conditions of supply are specified insubsequent Sections of this Chapter.

1.7.2 The manufacturer is to carry out any heat treatmentwhich may be necessary to prevent hydrogen cracking or tomake the material in a safe condition for transit. The Surveyoris to be advised of any heat treatment proposed.

1.7.3 Where material is manufactured using a thermo-mechanically controlled process consideration must be givento the possibility of consequent reduction in mechanical properties if it is subjected to heating for forming or stressrelieving or is welded using a high heat input.

Rolled Steel Plates, Strip, Sections and BarsRULES FOR THE MANUFACTURE, TESTING AND CERTIFICATION OF MATERIALS, July 2014

Chapter 3Section 1


Rolling direction

Thickness measurement point

Line 1

Line 2

Line 3

Fig. 3.1.1 Location of thickness measuring points

1.8.8 Impact test specimens are to be cut with their principal axes either parallel (longitudinal test) or perpendicular(transverse test) to the final direction of rolling, as required bysubsequent Sections of this Chapter. Where both longitudinaland transverse impact properties are shown for a particulargrade, only the longitudinal test is required to be carried out,unless otherwise specified by the purchase order or subsequent Sections of this Chapter. However, for plates andwide flats, by certifying that the product meets the requirementsof the Rules, the manufacturer guarantees that the acceptancevalues will be met if tested in the transverse direction. The Surveyor may request testing in this direction to confirm conformity.

1.8.9 Impact test specimens are to be of the CharpyV-notch type, machined to the dimensions detailed in Chapter 2. They are to be taken from a position within 2 mmof one of the rolled surfaces, except that for plates andsections over 40 mm thick, the axes of the test specimensare to be at one-quarter of the thickness from one of the rolledsurfaces. For bars and other similar products the axes of thetest specimens are to be as specified in 1.8.4(d).

1.8.10 Standard test specimens 10 mm square are to beused, except where the thickness of the material does notallow this size of test specimen to be prepared. In such casesthe largest possible size of subsidiary test specimen, in accor-dance with Table 2.3.1 is to be prepared, with the notch cuton the narrow face. Alternatively, for material of suitable thickness, the rolled surfaces may be retained so that the testspecimen width will be the full thickness of the material. Insuch cases the tolerances for width given in Table 2.3.1 inChapter 2 are not applicable. The notch is to be cut in a faceof the test specimen which was originally perpendicular to therolled surface. The position of the notch is to be not nearerthan 25 mm to a flame-cut or sheared edge.

1.8.11 Impact tests are not required when the nominalmaterial thickness is less than 6 mm.

1.8.12 The test procedures used for all tensile and impacttests are to be in accordance with the requirements ofChapter 2.

1.9 Visual and non-destructive examination

1.9.1 Surface inspection and verification of dimensionsare the responsibility of the steelmaker and are to be carriedout on all material prior to despatch. Acceptance by theSurveyors of material later found to be defective shall notabsolve the steelmaker from this responsibility.

1.9.2 With the exception of ‘Z’ grade plate material (seeSection 8) and bars for offshore mooring cable (seeSection 9), the non-destructive examination of materials is notrequired for acceptance purposes, see also 1.5.1. However,manufacturers are expected to employ suitable methods ofnon-destructive examination for the general maintenance ofquality standards.

1.8 Test material and mechanical tests

1.8.1 Depending on the type of product, provision ismade in subsequent Sections of this Chapter for the testing ofindividual items or for batch testing. Where the latter is permitted, all materials in a batch presented for acceptancetests are to be of the same product form, (e.g., plates, flats,sections, etc.), from the same cast and in the same conditionof supply.

1.8.2 The test samples are to be fully representative ofthe material and, where appropriate, are not to be cut fromthe material until heat treatment has been completed. The testspecimens are not to be separately heat treated in any way.

1.8.3 The test material is to be taken from the thickestpiece in each batch, see Ch 1,4.1.

1.8.4 Test material is to be taken from the following positions:(a) At the square cut end of plates and flats greater than

600 mm wide, approximately one-quarter width from anedge, see Fig. 3.1.2(a).

(b) For flats 600 mm or less in width, bulb flats and othersolid sections, at approximately one-third of the widthfrom an edge, see Fig. 3.1.2(b), (c) and (d). Alternatively,in the case of channels, beams or bulb angles, atapproximately one-quarter of the width from the centreline of the web, see Fig. 3.1.2(c).

(c) For rectangular hollow sections, at approximately thecentre of any side, see Fig. 3.1.2(e). For circular hollowsections, at any position on the periphery.

(d) For bars intended for purposes as detailed in Sections 2,3, 5 and 9, at approximately one-third of the radius orhalf-diagonal from the outer surface, see Fig. 3.1.2(f).For smaller bars, the position of the test material is to beas close as is possible to the above.

(e) For bars intended for the applications detailed inSections 4, 6 and 7 at approximately 12,5 mm below thesurface. For bars up to 25 mm diameter, the test specimens may be machined coaxially.

(f) For plates and flats with thicknesses in excess of40 mm, full thickness specimens may be prepared, butwhen instead a machined round specimen is used thenthe axis is to be located at a position lying one-quarter ofthe product thickness from the surface as shown in Fig. 3.1.2(g).

1.8.5 Tensile test specimens and impact test specimens,where required for the type and grade of product being supplied, are to be prepared from each item or batch ofmaterial submitted for acceptance.

1.8.6 Where the finished width of plates and flats isgreater than 600 mm, the tensile test specimens are to be cutwith their principal axes perpendicular to the final direction ofrolling. For all other rolled products, the principal axes are tobe parallel to the final direction of rolling.

1.8.7 The tensile test specimens are to be machined tothe dimensions detailed in Ch 2,2.1.6 and 2.1.7.


Chapter 3Section 1

LLOYD’S REGISTER4

(f) Rounds

radius

(e) Hollow rectangular sections(d) Bulb flats

(c) Channels and beams

t

t

(g) Plates and flats with thickness exceeding 40 mm

(b) Angles

13

13

13

12

14

12

12

13

14

(a) Plates and flats

Square cut end

Discard

14

2665/20


Chapter 3Section 1


Fig. 3.1.2 Position of test material

1.10.4 For plates which have been produced by a T.M.process or by normalising rolling, repair by welding will beapproved by the Surveyor only after procedure tests haveshown that the mechanical properties have not beenimpaired.

1.10.5 Cracks, shells, sand patches and sharp edgedseams are always considered defects which would impair theend use of the product and which require rejection or repairirrespective of their size and number. The same applies toother imperfections exceeding the acceptable limits.


1.11.1 Every finished item is to be clearly marked by the manufacturer in at least one place with LR’s brand and the following particulars:(a) The manufacturer’s name or trade mark.(b) The grade of steel. The designations given in sub-

sequent Sections of this Chapter may be preceded bythe letters ‘LR’ in order to fully describe the grade, e.g. LR A, LR 490FG. LR LT-FH40, LR 316L, etc.

(c) When the material complies with the requirements ofSection 8, the grade is to include the suffix Z25 or Z35,e.g., LR AH36 Z35.

(d) Identification number and/or initials which will enable thefull history of the item to be traced.

(e) If required by the purchaser, his order number or otheridentification mark.

The above particulars, but excluding the manufacturer’s nameor trade mark where this is embossed on finished products,are to be encircled with paint or otherwise marked so as tobe easily recognisable.

1.11.2 Where a number of light materials are securelyfastened together in bundles, the manufacturer may brandonly the top piece of each bundle or, alternatively, a firmlyfastened durable label containing the identification may beattached to each bundle.

1.11.3 In the event of any material bearing LR’s brand failing to comply with the test requirements, the brand is to beunmistakably defaced, see also Ch 1,4.8.

1.12 Certification of materials

1.12.1 Unless a LR certificate is specified in other parts ofthe Rules, a manufacturer’s certificate validated by LR is to beissued (see Ch 1,3.1) and is to include the following particulars:(a) Purchaser’s name and order number.(b) If known, the contract number for which the material is

intended.(c) Address to which material is dispatched.(d) Name of steelworks.(e) Description and dimensions of the material.(f) Specification or grade of the steel.(g) Identification number of piece, including test specimen

number where appropriate.(h) Cast number and chemical composition of ladle

samples.

1.10 Rectification of defects

1.10.1 For materials intended for structural purposes asdetailed in Sections 2, 3 and 5, surface defects may beremoved by local grinding provided that:(a) the thickness is in no place reduced to less than 93 per

cent of the nominal thickness, but in no case by morethan 3 mm,

(b) each single ground area does not exceed 0,25 m2,(c) the total area of local grinding does not exceed two per

cent of the total surface,(d) the ground areas have smooth transitions to the

surrounding surface. Where necessary, the entire surface may be ground to a maximum depth as given by the underthickness tolerancesof the product. The extent of such rectification is to be agreedin each case with the Surveyors and is to be carried out undertheir supervision, unless otherwise agreed. They may requestthat complete removal of the defect is proven by suitable non-destructive examination of the affected area.

1.10.2 Surface defects which cannot be dealt with as in1.10.1 may be repaired by chipping or grinding followed bywelding, subject to the Surveyor’s consent and under hissupervision, provided that:(a) after removal of the defect and before welding, the

thickness of the item is in no place reduced by morethan 20 per cent,

(b) each single weld does not exceed 0,125 m2,(c) the total area of welding does not exceed two per cent

of the surface of the side involved,(d) the distance between any two welds is not less than

their average width,(e) the welds are of reasonable size and made with an

excess layer of beads which is then ground smooth tothe surface level,

(f) elimination of the defect is proven by suitable non-destructive examination of the affected area,

(g) welding is carried out by an approved procedure and bycompetent operators using approved electrodes and therepaired area is ground smooth to the correct nominalthickness,

(h) when requested by the Surveyor, the item is normalisedor otherwise suitably heat treated after welding andgrinding, and

(j) at the discretion of the Surveyor, the repaired area isproven free from defects by suitable non-destructiveexamination.

1.10.3 For materials intended for applications as detailedin Sections 4, 6 and 7, surface defects may be removed bygrinding in accordance with 1.10.1, except that when the thickness is reduced below that given in the approved plans,acceptance will be subject to special consideration. Weldrepairs may also be carried out generally in accordance with1.10.2, except that in all cases suitable heat treatment afterwelding and non-destructive testing of the repaired areas isrequired. The fabricator is to be advised regarding the position and extent of all repairs.


Chapter 3Section 1

LLOYD’S REGISTER6

(j) Mechanical test results (not required on shipping statements).

(k) Condition of supply.

1.12.2 Before the test certificates are signed by theSurveyor, the steelmaker is required to provide a written declaration stating that the material has been made by anapproved process, and that it has been subjected to and haswithstood satisfactorily the required tests in the presence ofthe Surveyor, or an authorised deputy. The following form ofdeclaration will be accepted if stamped or printed on eachtest certificate with the name of the steelworks and signed byan authorised representative of the manufacturer:

‘We hereby certify that the material has been made byan approved process and satisfactorily tested in accordance with the Rules of Lloyd’s Register’.

1.12.3 When steel is not produced at the works at which itis rolled, a certificate is to be supplied by the steelmaker stating the process of manufacture, the cast number and thechemical composition of ladle samples. The works at whichthe steel was produced must be approved by LR.

1.12.4 The manufacturer of coiled plate is required to issuea certificate which clearly identifies the material as coil. Thecertificate issued should include the words; ‘Coils covered bythis certificate require further processing at a works approvedby Lloyd’s Register before being certified as plate in accor-dance with the Rules of Lloyd’s Register’ in addition to therequirements of 1.12.2.

1.12.5 The supplier of plate cut from coil is required to issuea certificate which clearly identifies the product as finishedplate meeting the requirements of the Rules in accordancewith 1.12.2.

1.12.6 The form of certificates produced by computersystems is to be agreed with the Surveyor.

■ Section 2Normal strength steels for shipand other structural applications

2.1 Scope

2.1.1 The requirements of this Section are primarilyintended to apply to steel plates and wide flats not exceeding100 mm in thickness and sections and bars not exceeding 50 mm in thickness in Grades A, B, D and E. For greaterthicknesses, variations in the requirements may be permittedor required for particular applications.

2.1.2 Additional approval tests may be required to verifythe suitability for forming and welding of Grade E plateexceeding 50 mm in thickness.

2.2 Manufacture and chemical composition

2.2.1 The method of deoxidation and the chemicalcomposition of ladle samples are to comply with the require-ments given in Table 3.2.1.

2.2.2 Small variations from the chemical compositionsgiven in Table 3.2.1 may be allowed for Grade E steel in thicknesses exceeding 50 mm or when any Grade of steel issupplied in a thermo-mechanically controlled processedcondition, provided that these variations are documented andapproved in advance.

2.2.3 The manufacturer’s declared analysis will beaccepted subject to occasional checks if required by theSurveyors.

2.2.4 For plate supplied from coil, the chemical analysiscan be transposed from the certificate of the coil manufactureonto the re-processor’s certificate.

2.3 Condition of supply

2.3.1 All materials are to be supplied in a conditioncomplying with the requirements given in Table 3.2.2. Wherealternative conditions are permitted these are at the option ofthe steelmaker, unless otherwise expressly stated in the orderfor the material, but a steelmaker is to supply materials only inthose conditions for which he has been approved by LR.

2.3.2 Where normalising rolling and thermomechanicallycontrolled rolling (T.M.) processes are used, it is the manu-facturer’s responsibility to ensure that the programmed rollingschedules are adhered to. Where deviation from theprogrammed rolling schedule occurs, the manufacturer mustensure that each affected piece is tested and that the localSurveyor is informed.

2.3.3 If a steel product supplied in the T.M. condition isto be subjected to heating for forming or stress relieving or isto be welded by a high energy input process, considerationmust be given to the possibility of a consequent reduction inmechanical properties.


2.4.1 The results of all tensile tests and the average energy value from each set of three impact tests are to comply with the appropriate requirements given in Table 3.2.3except where enhanced by the requirements of this Section.




2.4.2 With the exception given in 2.4.4, one tensile test isto be made for each batch presented unless the mass offinished material is greater than 50 tonnes, in which case onetest is to be made from a different piece from each 50 tonnesor fraction thereof. Additional tests are to be made for everyvariation of 10 mm in the thickness or diameter of productsfrom the same cast. For sections, the thickness to be considered is the thickness of the product at the point atwhich samples are taken for mechanical tests. A piece is tobe regarded as the rolled product from a single slab or billet,or from a single ingot if this is rolled directly into plates, strip,sections or bars.

2.4.3 For Grades A and B where plate is supplied fromcoil, results of the tensile test can be transposed from thecertificate of the coil manufacture onto the certificate issued bythe re-processor. If the coil mass exceeds 50 tonnes, testing will additionally be required from two locations representing thestart and end of the coil. For Grades D and E, the mechanicalproperties must be sampled from the de-coiled plate in accor-dance with the frequency specified in the Rules.

2.4.4 For plates of thickness exceeding 50 mm in Grade E steel, one tensile test is to be made on each piece.


Chapter 3Section 2

LLOYD’S REGISTER8

Table 3.2.2 Condition of supply

Grade Thickness, mm Conditions of supply

≤50 Any (see Note 1)A and B

>50 ≤100 N NR TM (see Note 2)

≤35 Any (see Note 1)D

>35 ≤100 N NR TM (see Note 3)

E ≤100 N TM (see Note 4)

N = normalisedNR = normalising rolledTM = thermomechanically controlled-rolled

NOTES1. ‘Any’ includes as-rolled, normalised, normalising rolled and

thermomechanically controlled-rolled.2. Plates, wide flats, sections and bars may be supplied in the

as-rolled condition, subject to special approval from LR.3. Sections in Grade D steel may be supplied in thicknesses

greater than 35 mm in the as-rolled condition provided thatsatisfactory results are consistently obtained from Charpy V-notch impact tests.

4. Sections in Grade E steel may be supplied in the as-rolledand normalising rolled conditions provided that satisfactoryresults are consistently obtained from Charpy V-notchimpact tests.

Table 3.2.1 Chemical composition and deoxidation practice

Grade A B D E

For t ≤ 50 mm: For t ≤ 50 mm: For t ≤ 25 mm:Any method (for rimmed Any method except Killed

steel, see Note 1) rimmed steel Killed and fineDeoxidation grain treated

For t > 50 mm: For t > 50 mm: For t > 25 mm: with aluminiumKilled Killed Killed and fine grain

treated with aluminium

Chemical composition %(see Note 5)

Carbon 0,21 max. (see Note 2) 0,21 max. 0,21 max. 0,18 max.Manganese 2,5 x C% min. 0,80 min. (see Note 3) 0,60 min. 0,70 min.Silicon 0,50 max. 0,35 max. 0,10 – 0,35 0,10 – 0,35Sulphur 0,035 max. 0,035 max. 0,035 max. 0,035 max.Phosphorus 0,035 max. 0,035 max. 0,035 max. 0,035 max.Aluminium — — 0,015 min. (see Note 4) 0,015 min. (see Note 4)

(acid soluble)

Carbon + 1/6 of the manganese content is not to exceed 0,40%

NOTES1. For Grade A, rimmed steel may only be accepted for sections up to a maximum thickness of 12,5 mm, provided that it is stated on the

test certificates or shipping statements to be rimmed steel.2. The maximum carbon content for Grade A steel may be increased to 0,23% for sections.3. Where Grade B is impact tested the minimum manganese content may be reduced to 0,60%.4. The total aluminium content may be determined instead of the acid soluble content. In such cases the total aluminium content is to be

not less than 0,020%.5. Where additions of any other elements are made as part of the steel-making practice, the content is to be recorded.

2.4.5 For Grade A steel, Charpy V-notch impact tests arenot required when the thickness does not exceed 50 mm, orup to 100 mm thick if the material is supplied in either thenormalised or thermo-mechanically controlled-rolled conditionand has been fine grain treated. However, the manufacturershould confirm, by way of regular in-house checks, that thematerial will meet a requirement of 27 J at +20°C. The resultsof these checks shall be reported to the Surveyor. Thefrequency of these checks should as a minimum be every 250 tonnes.

2.4.6 When Grade A steel is supplied in a thicknessgreater than 50 mm and either, in the normalising rolled condition, or when special approval has been given to supplyin the as-rolled condition, a set of three impact test specimensis to be tested from each batch of 50 tonnes or fractionthereof.

2.4.7 Impact tests are not required for Grade B steel of25 mm or less in thickness. However, the manufacturer is toconfirm, by way of regular in-house tests, and on occasionalmaterial selected by the Surveyor, that the material meets therequirement in Table 3.2.3. The results of the tests are to bereported to the Surveyor. The frequency of the in-housechecks are to be, as a minimum, one set of three impact testspecimens for every 250 tonnes.

2.4.8 For Grade B steels of thicknesses above 25 mm,supplied in the as-rolled or normalising rolled condition, oneset of three impact test specimens is to be made from thethickest item in each batch presented. If the mass of finishedmaterial is greater than 25 tonnes, one extra set of tests is tobe made from a different piece from each 25 tonnes or fraction thereof.

2.4.9 For Grade B steels of thicknesses above 25 mm,supplied in the furnace normalised or thermomechanicallycontrolled-rolled condition, one set of three impact test specimens is to be made from the thickest item in each batchpresented. If the mass of finished material is greater than 50 tonnes, one extra set of tests is to be made from a different piece from each 50 tonnes or fraction thereof.

2.4.10 For Grade D steels supplied in the as-rolled ornormalising rolled condition, one set of three impact test specimens is to be made from the thickest item in each batchpresented. If the mass of finished material is greater than 25 tonnes, one extra set of tests is to be made from a different piece from each 25 tonnes or fraction thereof.

2.4.11 For Grade D steels, supplied in the furnace normalised or thermomechanically controlled-rolled condition,one set of three impact test specimens is to be made from thethickest item in each batch presented. If the mass of finishedmaterial is greater than 50 tonnes, one extra set of tests is tobe made from a different piece from each 50 tonnes or fractionthereof.

NOTES1. For sections in Grade A, the upper limit of the tensile strength range may be exceeded at the discretion of the Surveyor.2. For full thickness tensile test specimens with a width of 25 mm and a gauge length of 200 mm (see Fig. 2.2.4 in Chapter 2), the

minimum elongation is to be:

3. Tests are to be taken in the longitudinal direction. Normally, transverse test specimens are not required. Transverse test results forplates and wide flats are to be garenteed by the supplier.

4. See 2.4.5 and 2.4.6.5. See 2.4.7.6. See 1.8.11.7. See 2.4.14.


Chapter 3Section 2


Table 3.2.3 Mechanical properties for acceptance purposes

Charpy V-notch impact test(see Notes 3, 4, 5, 6 and 7)

Thickness mm >5 >10 >15 >20 >25 >30 >35≤5 ≤10 ≤15 ≤20 ≤25 ≤30 ≤35 ≤50

Elongation % 14 16 17 18 19 20 21 22

Thicknessmm

≤50

>50 ≤70

>70 ≤100

Longitudinal

27

34

41

Transverse(see Note 3)

20

24

27

Average energy J minimumGrade

A

B

D

E

Yield stressN/mm2

minimum

235 400 – 520(see Note 1)

22(see Note 2)

Tensile strengthN/mm2

Elongation on

5,65 So% minimum

Impact tests are to be made on the various grades at the following temperatures: A grade not requiredB grade 0°CD grade –20°CE grade –40°C

2.4.12 For plates in Grade E steel, one set of three impacttest specimens is to be made from each piece. For bars andsections in Grade E steel, one set of three test specimens isto be made from each 25 tonnes or fraction thereof. When,subject to the special approval of LR, sections are suppliedin the as-rolled or normalising rolled conditions, one set ofimpact tests is to be taken from each batch of 15 tonnes orfraction thereof.

2.4.13 The results of all tensile tests and the averageenergy values from each set of three impact tests are tocomply with the appropriate requirements given in Table 3.2.3.For impact tests, one individual value may be less than therequired average value provided that it is not less than 70 percent of this average value. See Ch 1,4.6 for re-test procedures.

2.4.14 For batch tested Grade B and D steel platessupplied in a condition other than furnace normalised, with athickness equal to, or greater than 25 mm and 12 mmrespectively, and where the average value of one set of testsis less than 40 J, two further items from the same batch are tobe selected and tested. If these fail to achieve an average of40 J on either set, each individual piece of the heat is to betested. The plates are acceptable provided they meet therequirements of Table 3.2.3. Additional testing is not requiredwhere the manufacturer can demonstrate to the satisfactionof the Surveyor that the plate was rolled outside the limits ofthe programmed rolling schedule. In this instance the plateshould be rejected, see also 2.3.2.

2.4.15 Where standard subsidiary Charpy V-notch testspecimens are necessary, see Ch 2,3.2.4.


2.5.1 The particulars detailed in 1.11 are to be markedon all materials which have been accepted. Where a numberof light materials are bundled, the bundle is to be identified inaccordance with 1.11.2.


2.6.1 At least two copies of each test certificate are to beprovided. They are to be of the type and give the informationdetailed in 1.12 and, additionally, are to indicate if sections inGrade A steel of rimming quality have been supplied. As aminimum, the chemical composition is to include the contentsof any grain refining elements used and the residual elements,as detailed in Table 3.2.1.

■ Section 3Higher strength steels for shipand other structural applications

3.1 Scope

3.1.1 Provision is made for material to be supplied in fourstrength levels, 27S, 32, 36 and 40.


3.1.2 Provisions for material supplied in H47 strengthgrades are specifically intended for hatch comings and deckstructure of container ships.

3.1.3 The required notch toughness is designated bysubdividing the strength levels into Grades AH, DH, EH andFH.

3.1.4 For the designation to fully identify a steel and itsproperties the appropriate grade letters should precede thestrength level number, e.g. AH32 or FH40.

3.1.5 The requirements of this Section are primarilyintended to apply to plates, wide flats, sections and bars notexceeding the thickness limits given in Table 3.3.1. For greaterthicknesses, variations in the requirements may be permittedor required for particular applications but a reduction of therequired impact energy is not allowed.

3.1.6 It should be noted that the fatigue strength of weldments in steels of high strength levels may not be greaterthan those of steels of lower strength levels.

3.2 Alternative specifications

3.2.1 Steels differing from the requirements of thisSection in respect of chemical composition, deoxidation practice, condition of supply or mechanical properties may beaccepted subject to special approval by LR. Such steels areto be given a special designation, see 3.7.2.




Table 3.3.1 Maximum thickness limits

Maximum thicknessmm

Steel designationPlates and Sectionswide flats and bars

AH 27S DH 27S EH 27S FH27S

AH 32 DH 32 EH 32 FH32100 50

AH 36 DH 36 EH 36 FH36 (seeNote 1)

AH 40 DH 40 EH40 FH40

(see Note 2) EH 47 Notapplicable

NOTES1. Where the thickness exceeds 50 mm, the steel must initially

be approved by way of a Nil Ductility Test, in accordancewith ASTM E208, to show adequate crack arrest properties.The Nil Ductility Test Temperature is to be agreed for thethickness approved to ensure the crack arrest temperatureis below the minimum design temperature. Where the thick-ness exceeds 70 mm and the material is used specificallyas a crack arrest plate, the material must be speciallyapproved with a crack arrest fracture toughness Kca ≥ 6000 N/mm1,5.

2. Minimum thickness for H47 strength level is 50 mm, see 3.1.2.

3.3 Manufacture

3.3.1 All the grades of steel are to be in the killed and finegrain treated condition.


3.4.1 The chemical compositions of ladle samples for allgrades of steel are to comply with the requirements given inTable 3.3.2. The requirements for H47 strength grade steelsare given in Table 3.3.3.

3.4.2 The carbon equivalent is to be calculated from theladle analysis using the formula given below and is not toexceed the maximum value agreed between the fabricatorand the steelmaker when the steel is ordered.

Carbon equivalent = C + + +

For TM steels, the agreed carbon equivalent is not to exceedthe values given in Table 3.3.4.

Mn6

Cr + Mo + V5

Ni + Cu15

3.4.3 The cold cracking susceptibility, Pcm, may be usedinstead of the carbon equivalent for evaluating weldability, inwhich case the following formula is to be used for calculatingthe Pcm from the ladle analysis:

Pcm = C + + + + + + 5B

The maximum allowable Pcm is to be agreed with LR and is tobe included in the manufacturing specification and reportedon the certificate.

3.4.4 The cold cracking susceptibility, Pcm, is to have amaximum value of 0,22 per cent for steels of H47 strengthgrade.

3.4.5 Small deviations in chemical composition from thatgiven in Table 3.3.2 for plates exceeding 50 mm in thicknessin Grades EH36, EH40, FH36 and FH40 may be approvedprovided that these deviations are documented and approvedin advance.

3.4.6 Where the grain refining elements Niobium,Titanium and Vanadium are used either singly or in combina-tion, the chemical composition is to be specifically approvedfor each Grade in combination with the rolling procedure tobe used.

Si30

Mn + Cr + Cu20

Ni60

Mo15

V10




Chapter 3Section 3

Grades AH, DH, EH FH

Carbon % max. 0,18 0,16Manganese % 0,9 – 1,60 (see Note 1) 0,9 – 1,60Silicon % max. 0,50 0,50Phosphorus % max. 0,035 0,025Sulphur % max. 0,035 0,025

Grain refining elements (see Note 2)

Aluminium(acid soluble) % 0,015 min. (see Note 3)

Niobium % 0,02 – 0,05Vanadium % 0,05 – 0,10Titanium % 0,02 max.

Total (Nb + V + Ti) % 0,12 max.(see Note 5)

Residual elements

Nickel % max. 0,40 0,80Copper % max. 0,35 0,35Chromium % max. 0,20 0,20Molybdenum % max. 0,08 0,08Nitrogen % max. 0,009 (0,012 max.

if Al is present)

NOTES1. For AH grade steels in all strength levels and thicknesses up to 12,5 mm, the specified minimum manganese content is 0,70%.2. The steel is to contain aluminium, niobium, vanadium or other suitable grain refining elements, either singly or in any combination.

When used singly, the steel is to contain the specified minimum content of the grain refining element. When used in combination, thespecified minimum content of each element is not applicable.

3. The total aluminium content may be determined instead of the acid soluble content. In such cases the total aluminium content is to benot less than 0,020%.

4. Alloying elements other than those listed above are to be included in the approved manufacturing specification.5. The grain refining elements are to be in accordance with the approved specification.

Table 3.3.2 Chemical composition

3.4.7 When any grade is supplied in an approved thermomechanically controlled processed condition, variationsin the specified chemical composition may be considered,provided that these variations are documented and approvedin advance.

3.4.8 For plate supplied from coil, the chemical analysiscan be transposed from the certificate of the coil manufactureonto the re-processor’s certificate.

3.5 Condition of supply

3.5.1 All materials are to be supplied in a conditioncomplying with the requirements given in Table 3.3.5 or Table 3.3.6. Where alternative conditions are permitted, theseare at the option of the steelmaker, unless otherwise expresslystated in the order for the material.

3.5.2 Where normalising rolling and thermomechanicallycontrolled rolling (T.M.) processes are used, it is the manufacturer’s responsibility to ensure that the programmedrolling schedules are adhered to. Where deviation from theprogrammed rolling schedule occurs, the manufacturer mustensure that each affected piece is tested and that the localSurveyor is informed.

3.5.3 The use of precipitation hardening steels is notacceptable, except where such hardening is incidental to theuse of grain refining elements.


3.6.1 The results of all tensile tests and the averageenergy value from each set of three Charpy V-notch impacttests are to comply with the appropriate requirements given inTable 3.3.7 except where enhanced by the requirements ofthis Section.

3.6.2 For steels in the as-rolled, normalised, normalisingrolled or T.M. conditions, one tensile test is to be made foreach batch of 50 tonnes or fraction thereof. Additional testsare to be made for every variation of 10 mm in the thicknessor diameter of products from the same cast.

3.6.3 Where plate is supplied from coil, both the tensiletests and the Charpy V-notch tests are to be taken from thede-coiled plate in accordance with the frequency specified forthe Grade as required by this Section.

3.6.4 For steels in the quenched and tempered conditiona tensile test is to be made on each plate as heat treated. Forcontinuously heat treated plates, one tensile test is to bemade for each 50 tonnes or fraction thereof from a singlecast. Additional tests are to be made for every variation of 10 mm in the thickness of the products from a single cast.The tensile test specimens are to be taken with their axestransverse to the main direction of rolling.




Chapter 3Section 3

Table 3.3.4 Carbon equivalent requirements for higher tensile strength steels up to 100 mm in thickness whensupplied in the TM condition

Table 3.3.3 Chemical composition for Grade EH 47

Chemical element max. (%)

Carbon 0,20

Manganese 2,00

Silicon 0,55

Phosphorus 0,030

Sulphur 0,030

Nickel 2,00

Chromium 0,25

Molybdenum 0,080

Grain refining elements (see Note 1)Aluminium (acid soluble) 0,015 min (see Note 2)

Residual elementsCopper 0,35

NOTES1. The grain refining elements niobium, vanadium and titanium

are to be in accordance with the approved specification.2. The total aluminium content may be determined instead of

the acid soluble content. In these cases the total aluminiumcontent is to be not less than 0,020%.

Carbon Equivalent, max. (%)Grade

t ≤ 50 50 < t ≤ 100

AH 27S DH 27S EH 27S FH 27S 0,36 0,38AH 32 DH 32 EH 32 FH 32 0,36 0,38AH 36 DH 36 EH 36 FH 36 0,38 0,40AH 40 DH 40 EH 40 FH 40 0,40 0,42

EH 47 Not applicable (see Table 3.3.1) 0,49

NOTEt = thickness, in mm.

3.6.5 For products in the AH and DH grades, at least oneset of three impact tests is to be made on the thickest piecein each batch of 50 tonnes when supplied in either thenormalised or thermomechanically controlled condition. Whenthe products are supplied in the as-rolled or normalising rolledconditions a set of impact test specimens is to be taken froma different piece from each 25 tonnes or fraction thereof.When supplied in the quenched and tempered condition, aset of impact tests is to be made on each length as heattreated. Test specimens from the quenched and temperedplates are to have their axes transverse to the main rollingdirection.

3.6.6 For plates and wide flats in the EH and FH gradessupplied in the normalised or thermomechanically controlledconditions, one set of impact tests is to be made on eachpiece. For plates supplied in the quenched and temperedcondition a set of impact tests is to be made on each lengthas heat treated. Test specimens from the quenched andtempered plates are to have their axes transverse to the mainrolling direction.

3.6.7 For plates and wide flats in H47 strength grade,one set of impact tests is to be made on each piece.

3.6.8 For sections and bars in the EH and FH gradessupplied in the normalised or thermomechanically controlledconditions, one set of impact tests is to be made on the thickestpiece in a batch not exceeding 25 tonnes. For sectionssupplied in the as-rolled or normalising rolled conditions thebatch size is not to exceed 15 tonnes.




Chapter 3Section 3

Grain refining practice Thickness range Conditions of supply(see Note 1) mm (see Note 2)

Table 3.3.5 Conditions of supply for plates and wide flats

AH 27SAH 32AH 36

AH 40

DH 27SDH 32DH 36

DH 40

EH 40

FH 27SFH 32FH 36FH 40

EH 27SEH 32EH 36

Al orAl + Ti

Nb or V orAl + (Nb or V) or

Al + (Ti) + (Nb or V)

Al orAl + Ti

Nb or V orAl + (Nb or V) or

Al + (Ti) + (Nb or V)

Any practice

Any practice

Any practice

Any practice

Any practice

≤ 20

>20 ≤ 100

≤ 12,5

>12,5 ≤ 100

≤ 12,5

>12,5 ≤ 50

>50 ≤ 100

≤ 20

>20 ≤ 100

≤ 12,5

>12,5 ≤ 100

≤ 50>50 ≤ 100

≤ 100

≤ 100

≤ 100

≤ 50

>50 ≤100

AR

—

AR

—

AR

—

—

AR

—

AR

—

——

—

—

—

—

N

N

N

N

N

N

N

N

N

N

N

NN

N

N

N

—

NR

NR

NRNR

NR

NR

—

NR

NR

NR

NR

NR—

—

—

—

—

TM

TM

TM

TM

TM

TM

TM

TM

TM

TM

TM

TMTM

TM

TM

TM

TM

(see Note 3)

QT

(see Note 4)

QT

QT

QT

QT

NOTES1. Grain refining elements used singly or in any combination, require specific approval from Materials and NDE Department, London office.2. AR = as-rolled N = furnace normalised NR = normalising rolled

TM = thermomechanically controlled-rolled QT = quenched and tempered3. Material up to 35 mm thick may be supplied in the as-rolled condition provided that prior approval has been obtained from LR.4. Material up to 25 mm thick may be supplied in the as-rolled condition provided that prior approval has been obtained from LR.

EH 47 Any practice

Grade

Not applicable

Rolled Steel Plates, Strip, Sections and Bars Chapter 3Section 3


3.7.2 Steels which have been specially approved andwhich differ from the requirements of this Section are to havethe letter ‘S’ after the agreed identification mark.


3.8.1 At least two copies of each test certificate are to beprovided. They are to be of the type and give the informationdetailed in 1.12 and, additionally, are to state the specifiedmaximum carbon equivalent. As a minimum, the chemicalcomposition is to include the contents of any grain refiningelements used and of the residual elements.

3.8.2 For steels which have been specially approved, theagreed identification mark, the specified minimum yield stressand, if applicable, the contents of alloying elements are additionally to be stated on the test certificate or shippingstatement.

3.8.3 The steelmaker is to provide the Surveyor with awritten declaration as detailed in 1.12.2.

3.6.9 For batch tested plates in a condition other thanfurnace normalised, with a thickness equal to 12 mm orgreater, and where the average value of one set of tests is lessthan 50 J, two further items from the same batch are to beselected and tested. If these fail to achieve an average of 50 J on either set, each individual piece of the heat is to betested. The plates are acceptable provided they meet therequirements of Table 3.3.7. Additional testing is not requiredwhere the manufacturer can demonstrate to the satisfactionof the Surveyor that the plate was rolled outside the limits ofthe programmed rolling schedule. In this instance the plateshould be rejected, see also 3.5.2.

3.6.10 Where standard subsidiary impact specimens arenecessary, see Ch 2,3.2.4.


3.7.1 The particulars detailed in 1.11 are to be markedon all materials which have been accepted and, for ease ofrecognition, are to be encircled or otherwise marked withpaint. Where a number of light products are bundled, thebundle is to be identified in accordance with 1.11.2.


Table 3.3.6 Conditions of supply for sections and bars

GradeGrain refining practice Thickness range Conditions of supply

(see Note 1) mm (see Note 2)

AH 27SAH 32AH 36

AH 40

DH 27SDH 32DH 36

DH 40

EH 40

FH 27SFH 32FH 36FH 40

EH 27SEH 32EH 36

Al orAl + Ti

Nb or V orAl + Nb or Al + V orAl + (Ti) + (Nb or V)

Al orAl + Ti

Nb or V orAl + Nb or Al + V orAl + (Ti) + (Nb or V)

Any practice

Any practice

Any practice

Any practice

Any practice

≤20

>20 ≤50

≤12,5

>12,5 ≤50

≤12,5

>12,5 ≤50

≤20

>20 ≤50

≤12,5

>12,5 ≤50

≤50

≤50

≤50

≤50

Any

N

Any

N

Any

N

Any

N

Any

N

N

N

N

N

NR

NR

NR

NR

NR

NR

TM

TM

TM

TM

TM

TM

TM

TM

TM

QT

QT

(see Note 3)

(see Note 3)

(see Note 3)

(see Note 3)

(see Notes 3 and 4)

(see Note 4)

NOTES1. Grain refining elements used singly or in any combination require specific approval from Materials and NDE Department, London Office.2. N = furnace normalised NR = normalising rolled

TM = thermomechanically controlled-rolled QT = quenched and tempered3. Subject to the special approval of LR, sections may be supplied in the as-rolled condition provided satisfactory results are consistently

obtained from Charpy V-notch impact tests.4. Subject to the special approval of LR, sections may be supplied in the NR condition.




Chapter 3Section 3

ElongationYield Tensile

Grades Stress Strength on 5,65 So(see Note 3) N/mm2 N/mm2 % min.

min. (see Note 2)

Longitudinal Transverse Longitudinal Transverse Longitudinal Transverse

AH 27SDH 27S 265 400 – 530 22 27 20 34 24 41 27EH 27SFH 27S

AH 32DH 32 315 440 – 570 22 31 22 38 26 46 31EH 32FH 32

AH 36DH 36 355 490 – 630 21 34 24 41 27 50 34EH 36FH 36

AH 40DH 40 390 510 – 650 20 39 26 46 31 55 37EH 40 FH 40 (see Note 8) (see Note 8)

460 570 – 720 17 — — 53 35 64 42

(see Note 8) (see Note 8)

Impact tests are to be made on the various grades at the following temperatures:

AH grades 0°CDH grades –20°CEH grades –40°CFH grades –60°C

Charpy V-notch impact tests (see Notes 3, 4 and 5)

Average energyJ minimum

t ≤ 50 mm 50 < t ≤ 70 mm 70 < t ≤ 100 mm

Table 3.3.7 Mechanical properties for acceptance purposes (see Note 1) (continued)

EH 47

■ Section 4Steels for boilers and pressurevessels

4.1 Scope

4.1.1 Provision is made in this Section for carbon,carbon-manganese and alloy steels intended for use in theconstruction of boilers and pressure vessels. In addition tospecifying mechanical properties at ambient temperature forthe purposes of acceptance testing, these requirements alsogive details of appropriate mechanical properties at elevatedtemperatures which may be used for design purposes.

4.1.2 Where it is proposed to use a carbon or carbon-manganese steel with a specified minimum tensile strengthintermediate to those given in this Section, correspondingminimum values for the yield stress, elongation and mechanicalproperties at elevated temperatures may be obtained by interpolation.

4.1.3 Carbon and carbon-manganese steels with a specified minimum tensile strength of greater than 490 N/mm2

but not exceeding 520 N/mm2 may be accepted, provided thatdetails of the proposed specification are submitted for approval.

4.1.4 Where it is proposed to use alloy steels other thanas given in this Section, details of the specification are to besubmitted for approval. In such cases the specified minimumtensile strength is not to exceed 600 N/mm2.

4.1.5 Materials intended for use in the construction of thecargo tanks and process pressure vessels storage tanks forliquefied gases and for other low temperature applications areto comply with the requirements of Section 6 or 7, as appropriate.


4.2.1 The method of deoxidation and the chemicalcomposition of ladle samples are to comply with the appropriaterequirements of Table 3.4.1.





NOTES1. The requirements for products thicker than those detailed in the table are subject to agreement, see 3.1.4.2. For full thickness tensile test specimens with a width of 25 mm and a gauge length of 200 mm, see Fig. 2.2.4 in Chapter 2, the

minimum elongation is to be:

3. Subject to special approval by LR, the minimum tensile strength may be reduced to 470 N/mm2, for grades AH36, DH36, EH36 andFH36, in the TM condition when micro-alloying elements Nb, Ti or V are used singly and not in combination and provided the yield totensile strength ratio does not exceed 0,89. For plates with a thickness ≤12 mm, the yield to tensile strength ratio is to be specially considered.

4. Tests are to be taken in the longitudinal direction. Normally, transverse test specimens are not required. Transverse test results for plates and wideflats are to be guaranteed by the supplier.

5. See 1.8.116. See 3.6.9.7. For steel of H47 strength grade, the yield to tensile strength ratio is not to exceed 0,94.8. The Charpy V-notch impact energy for crack arrest steels of grade EH40, FH40 and EH47 intended for longitudinal strength members in

container ships in thickness between 85 mm and 100 mm are to be:

Table 3.3.7 Mechanical properties for acceptance purposes (conclusion)

Thickness mm ≤5 >5 >10 >15 >20 >25 >30 >40 >50≤10 ≤15 ≤20 ≤25 ≤30 ≤40 ≤50

Strength levels27S, 32 14 16 17 18 19 20 21 22

Elongation Strength level To be% 36 13 15 16 17 18 19 20 21 specially

agreedStrength level

40 12 14 15 16 17 18 19 20

{

85 < t ≤ 100 mmGrade

Longitudinal Transverse

AH40 75 J 50 JDH40EH40FH40EH47

4.2.2 For plate supplied from coil, the chemical analysismay be transposed from the certificate of the coil manufactureonto the re-processor’s certificate.

4.3 Heat treatment

4.3.1 All materials are to be supplied in a conditioncomplying with the requirements given in Table 3.4.2 exceptthat, when agreed, material intended for hot forming may besupplied in the as-rolled condition.




Chapter 3Section 4

Table 3.4.1 Chemical composition and deoxidation practice

Grade of steel Deoxidation Chemical composition %

Carbon and carbon-manganesesteels

Cmax. Si Mn P S Al Residual elements

360 AR

410 AR

460 AR

360

410

460

490

360 FG

410 FG

460 FG

490 FG

510 FG

Any methodexceptrimmed steel

Any methodexceptrimmed steel

Killed

Killed finegrained

0,18

0,21

0,23

0,17

0,20

0,20(see Note 1)

0,17

0,20

0,20(see Note 1)

0,22

0,50 max.

0,35 max.

0,40 max.

0,10 – 0,50

0,35 max.

0,40 max.

0,10 – 0,50

0,40 – 1,20

0,40 – 1,30

0,80 – 1,50

0,40 – 1,20

0,50 – 1,30

0,80 – 1,40

0,90 – 1,60

0,40 – 1,20

0,50 – 1,30

0,80 – 1,50

0,90 – 1,60

0,040 max.

0,035 max.

0,035 max.

–

–

–

–

–

–

–

(see Note2)

Cr 0,25 max.Cu 0,30 max.Mo 0,10 max.Ni 0,30 max.

Total 0,70 max.

Alloy steel C Si Mn P S Al Residual elementsCr Mo

13Cr Mo 45

11Cr Mo 910

Killed

0,10–0,18

0,08–0,18

0,15–0,35

0,15–0,50

0,4–0,8 0,035 max.

(seeNote 3)

0,70–1,30

2,00–2,50

0,40–0,60

0,90–1,10

Cu 0,30 max.

Ni 0,30 max.

NOTES1. For thicknesses greater than 30 mm, carbon 0,22% max.2. Aluminium (acid soluble) 0,015% min. or

Aluminium (total) 0,018% min.

Niobium, vanadium or other suitable grain refining elements maybe used either in place of or in addition to aluminium.

3. Aluminium (acid soluble or total) 0,020% max.

Grade of steel Condition of supply

Carbon andcarbon-manganese360 AR to 460 AR

Carbon andcarbon-manganese360 to 490

Carbon andcarbon-manganese360 FG to 510 FG

13Cr Mo 45

11Cr Mo 910

As-rolledMaximum thickness or diameter is 40 mm

Normalised or normalised rolled

Normalised or normalised rolled

Normalised and tempered


Table 3.4.2 Condition of supply


4.4.1 For plates, a tensile test specimen is to be takenfrom one end of each piece when the mass does not exceed5 tonnes and the length does not exceed 15 m. When eitherof these limits is exceeded, tensile test specimens are to betaken from both ends of each piece. A piece is to be regardedas the rolled product from a single slab or from a single ingotif this is rolled directly into plates.

4.4.2 For strip, tensile test specimens are to be takenfrom both ends of each coil.

4.4.3 Sections and bars are to be presented for accep-tance test in batches containing not more than 50 lengths, assupplied. The material in each batch is to be of the samesection size, from the same cast and in the same conditionof supply. One tensile test specimen is to be taken from materialrepresentative of each batch, except that additional tests areto be taken when the mass of a batch exceeds 10 tonnes.

4.4.4 Where plates are required for hot forming and it hasbeen agreed that the heat treatment will be carried out by thefabricator, the tests at the steelworks are to be made onmaterial which has been cut from the plates and given anormalising and tempering heat treatment in a manner simulating the treatment which will be applied to the plates.

4.4.5 If required by the Surveyors or by the fabricator, testmaterial may be given a simulated stress relieving heat treatment prior to the preparation of the test specimens. Thishas to be stated on the order together with agreed details ofthe simulated heat treatment and the mechanical propertieswhich can be accepted.

4.4.6 The results of all tensile tests are to comply with theappropriate requirements given in Tables 3.4.3 to 3.4.5.

4.4.7 Where plate is supplied from coil, the tensile testsare to be taken from the de-coiled plate in accordance withthe frequency specified for the Grade as required by thisSection.

4.4.8 All test specimens are to be taken in the transversedirection unless otherwise agreed.

4.4.9 When material will be subject to strains in a throughthickness direction, it is recommended that it should havespecified through thickness properties in accordance with therequirements of Section 8.


4.5.1 The particulars detailed in 1.11 are to be markedon all materials which have been accepted.


4.6.1 At least two copies of each test certificate are to beprovided. They are to be of the type and to give the informa-tion detailed in 1.12 and, additionally, are to state the specifiedmaximum carbon equivalent. As a minimum, chemicalcomposition is to include the content of any grain refiningelements used and of the residual elements, as detailed inTable 3.4.1.

4.7 Mechanical properties for design purposes

4.7.1 Nominal values for the minimum lower yield or 0,2 per cent proof stress at temperatures of 50°C and higherare given in Tables 3.4.6 to 3.4.8.

4.7.2 These values are intended for design purposesonly, and verification is not required except for materialscomplying with National or proprietary specifications wherethe elevated temperature properties used for design purposesare higher than given in Tables 3.4.6 to 3.4.8.

4.7.3 In such cases, at least one tensile test at theproposed design or other agreed temperature is to be madeon material from each cast. Where materials of more than onethickness are supplied from one cast, the thickest material is tobe tested. The test specimens are to be prepared from materialadjacent to that used for tests at ambient temperature. Theaxis of the test specimens, is to be between mid and quarterthickness of the material and the test specimens are to bemachined to dimensions in accordance with the requirementsof Chapter 2. The test procedure is also to be as detailed inChapter 2, and the results are to comply with the requirementsof the National or proprietary specifications.

4.7.4 As an alternative to 4.7.3, a manufacturer maycarry out an agreed comprehensive test program for a statedgrade of steel to demonstrate that the specified minimummechanical properties at elevated temperatures can beconsistently obtained. This test program is to be carried outunder supervision of the Surveyors, and the results submit-ted for assessment and approval. When a manufacturer isapproved on this basis, tensile tests at elevated temperaturesare not required for acceptance purposes but, at the discretion of the Surveyors, occasional check tests of thistype may be requested.

4.7.5 Values for the estimated average stress to rupturein 100 000 hours are given in Table 3.4.9 and may be usedfor design purposes.




Chapter 3Section 4

Yield Tensile ElongationGrade of Thickness stress strength on 5,65 So

steel mm N/mm2 N/mm2 % minimumminimum

360 AR 190 360–480 24

410 AR ≤ 40 215 410–530 22

460 AR 240 460–580 21} {

Table 3.4.3 Mechanical properties for acceptancepurposes: carbon and carbon-manganese steels – As-rolled




Chapter 3Section 4

Grade ofsteel

360

410

460

490

360 FG

410 FG

460 FG

490 FG

510 FG

Thicknessmm

(see Note)

>3 ≤16>16 ≤40>40 ≤63

>3 ≤16>16 ≤40>40 ≤63

>3 ≤16>16 ≤40>40 ≤63

>3 ≤16>16 ≤40>40 ≤63

>3 ≤16>16 ≤40>40 ≤63

>3 ≤16>16 ≤40>40 ≤63

>3 ≤16>16 ≤40>40 ≤63

>3 ≤16>16 ≤40>40 ≤63

>3 ≤16>16 ≤40>40 ≤63

Yield stressN/mm2

minimum

205195185

235225215

285255245

305275265

235215195

265245235

295285275

315315305

355345335

TensilestrengthN/mm2

360 – 480

410 – 530

460 – 580

490 – 610

360 – 480

410 – 530

460 – 580

490 – 610

510 – 650

Elongationon 5,65 So% minimum

262625

242423

222221

212120

262625

242423

222221

212121

21

NOTEFor thicknesses greater than 63 mm, the minimum values foryield stress may be reduced by 1% for each 5 mm increment inthickness over 63 mm. The minimum elongation values may alsobe reduced one unit, for all thicknesses over 63 mm. For thicknesses over 100 mm, the above values are to be agreed.

Table 3.4.4 Mechanical properties for acceptancepurposes: carbon and carbon-manganese steels – Normalised ornormalised rolled

Grade ofsteel

13Cr Mo45

11Cr Mo910

Thicknessmm

(see Note)

≤63

≤16>16 ≤63

Yieldstress

N/mm2

minimum

305

275265

TensilestrengthN/mm2

470–620

480–630

Elongationon 5,65 So% minimum

20

18

NOTEFor thicknesses greater than 63 mm, the minimum values foryield stress may be reduced by 1% for each 5 mm increment inthickness over 63 mm. The minimum elongation values mayalso be reduced one unit, e.g., for all thicknesses over 63 mm.For thicknesses over 100 mm, the above values are to beagreed.

Table 3.4.5 Mechanical properties for acceptancepurposes: alloy steels – Normalisedand tempered

Design temperature °C (see Note)

Grade of Thickness 50 100 150 200 250 300 350steel mm

Nominal minimum loweryield or 0,2% proof stress N/mm2

360 AR 154 153 152 145 128 108 102

410 AR ≤ 40 186 183 181 174 155 134 127

460 AR 218 213 210 203 182 161 153

NOTEMaximum permissible design temperature is 350°C.

} {

Table 3.4.6 Mechanical properties for designpurposes (see 4.7.1) : carbon andcarbon-manganese steels – As-rolled




Chapter 3Section 4

Table 3.4.7 Mechanical properties for design purposes (see 4.7.1): carbon and carbon-manganese steels – Normalised or controlled-rolled

Design temperature °C

50 100 150 200 250 300 350 400 450

Nominal minimum lower yield or 0,2% proof stress N/mm2

183 175 172 168 150 124 117 115 113173 171 169 162 144 124 117 115 113166 162 158 152 141 124 117 115 113

220 211 208 201 180 150 142 138 136204 201 198 191 171 150 142 138 136196 192 188 181 168 150 142 138 136

260 248 243 235 210 176 168 162 158235 230 227 220 198 176 168 162 158227 222 218 210 194 176 168 162 158

280 270 264 255 228 192 183 177 172255 248 245 237 214 192 183 177 172245 240 236 227 210 192 183 177 172

214 204 185 165 145 127 116 110 106200 196 183 164 145 127 116 110 106183 179 172 159 145 127 116 110 106

248 235 216 194 171 152 141 134 130235 228 213 192 171 152 141 134 130222 215 204 188 171 152 141 134 130

276 262 247 223 198 177 167 158 153271 260 242 220 198 177 167 158 153262 251 235 217 198 177 167 158 153

297 284 265 240 213 192 182 173 168293 279 260 237 213 192 182 173 168286 272 256 234 213 192 182 173 168

313 290 270 255 235 215 200 180 —

360

410

460

490

360 FG

410 FG

460 FG

490 FG

510 FG

>3 ≤16>16 ≤40>40 ≤63

>3 ≤16>16 ≤40>40 ≤63

>3 ≤16>16 ≤40>40 ≤63

>3 ≤16>16 ≤40>40 ≤63

>3 ≤16>16 ≤40>40 ≤63

>3 ≤16>16 ≤40>40 ≤63

>3 ≤16>16 ≤40>40 ≤63

>3 ≤16>16 ≤40>40 ≤63

>3 ≤63

NOTEFor thicknesses greater than 63 mm, the values for lower yield or 0,2% proof stress are to be reduced by 1% for each 5 mm increment in thickness up to 100 mm. For thicknesses over 100 mm, the values are to be agreed and verified by test.

Grade ofsteel

Thicknessmm

(see Note)

Table 3.4.8 Mechanical properties for design purposes (see 4.7.1): alloy steels – Normalised and tempered

Grade of steelThickness

mm(see Note)

Design temperature °C

50 100 200 300 350 400 450 500 550 600


284 270 248 216 203 199 194 188 181 174

255 249 233 219 212 207 194 180 160 137

13CrMo 45

11CrMo 910>3 ≤63

NOTEFor thicknesses greater than 63 mm, the values for lower yield or 0,2% proof stress are to be reduced by 1% for each 5 mm increment inthickness up to 100 mm. For thicknesses over 100 mm, the values are to be agreed and verified by test.

} {


5.2.1 At least two copies of each test certificate are to beprovided. They are to be of the type and give the informationdetailed in 1.12 and, additionally, are to state the specifiedmaximum carbon equivalent. As a minimum, chemical composition is to include the contents of any grain refining elements used and of the residual elements.

■ Section 6Ferritic steels for low temperatureservice

6.1 Scope

6.1.1 This Section gives specific requirements forcarbon-manganese and nickel alloy steels intended for use inthe construction of cargo tanks, storage tanks and processpressure vessels for liquefied gases.

6.1.2 The requirements of this Section are also applicablefor other types of pressure vessels where the use of steelswith guaranteed impact properties at low temperatures isrequired.

6.1.3 Provision is made for plates and sections up to 40 mm thick.

6.1.4 Steels with alternative chemical compositions ormechanical properties or in a different supply condition maybe given special consideration.


6.2.1 All steels are to be in the killed and fine grain treatedcondition.

6.2.2 The chemical compositions of carbon-manganesesteels are to comply with the appropriate requirements forGrades AH, DH, EH and FH strength levels 27S, 32, 36 and40, see Table 3.3.2. For the uses defined in 6.1.1 and 6.1.2,however, these grades are to be designated LT–AH, LT–DH,LT–EH and LT–FH respectively.

6.2.3 The chemical compositions of nickel alloy steels areto comply with the appropriate requirements of Table 3.6.1.

■ Section 5Steels for machinery fabrications

5.1 General

5.1.1 Steel plates, sections or bars intended for use inthe construction of major components of welded machinerystructures, such as bedplates, crankcases, frames andentablatures, are to comply with one of the following alternatives:(a) Any grade of normal strength structural steel as detailed

in Section 2.(b) Any grade of higher tensile structural steel as detailed in

Section 3.(c) Any grade of carbon-manganese boiler or pressure

vessel steel as detailed in Section 4, except that for thisapplication batch testing is acceptable. The size of abatch and the number of tensile tests are to be asdetailed in Section 2.

5.1.2 The minus tolerances for products for machinerystructures are to be in accordance with Table 3.5.1.

Rolled Steel Plates, Strip, Sections and Bars Chapter 3Sections 4, 5 & 6



Nominal thickness, t (mm) Minus tolerance (mm)

5 ≤ t < 8 –0,48 ≤ t < 15 –0,515 ≤ t <25 –0,625 ≤ t < 40 –0,8

t ≥ 40 –1,0

Table 3.5.1 Under thickness tolerancesTable 3.4.9 Mechanical properties for design purposes (see 4.7.5): estimated average values for stress to rupture in100 000 hours (units N/mm2)

Temperature °C

Grades of steel

Carbon andcarbon-manganese

360FG 360 490410FG 410 490FG460FG 460 510FG

13CrMo45

11CrMo910

380 171 219 227 — —390 155 196 203 — —400 141 173 179 — —

410 127 151 157 — —420 114 129 136 — —430 102 109 117 — —440 90 92 100 — —450 78 78 85 290 —

460 67 67 73 262 —470 57 57 63 235 210480 47 48 55 208 186490 36 — 47 181 165500 — — — 155 145

510 — — — 129 128520 — — — 103 112530 — — — 80 98540 — — — 62 84550 — — — 49 72

560 — — — 42 61570 — — — 36 51580 — — — — 44

Low alloy

6.4.3 Sections and bars are to be presented for accep-tance test in batches containing not more than 50 lengths, assupplied. The material in each batch is to be of the samesection size, from the same cast and in the same conditionof supply. One tensile test specimen is to be taken from material representative of each batch, except that additionaltests are to be taken when the mass of a batch exceeds 10 tonnes.

6.4.4 One set of three Charpy V-notch impact test specimens is to be taken for each tensile test specimenrequired.

6.4.5 For plates, these impact test specimens are to becut with the principal axis perpendicular to the final directionof rolling. For sections, the impact test specimens are to betaken longitudinally.

6.4.6 The results of all tensile tests are to comply with theappropriate requirements given in Table 3.6.3. The ratiobetween the yield stress and the tensile strength is not toexceed 0,9 for normalised and TM steels and 0,94 for QT steels.

6.4.7 The average value for the three impact tests is tocomply with the appropriate requirements given in Table 3.6.3. One individual value may be less than therequired value provided that it is not less than 70 per cent ofthis average value. See Ch 2,1.4 for re-test procedures.

6.4.8 Where standard subsidiary impact specimens arenecessary, see Ch 2,3.2.4.

6.4.9 Where plate is supplied from coil, both the tensiletests and the Charpy V-notch tests are to be taken from thede-coiled plate in accordance with the frequency specified forthe Grade as required by this Section.


6.5.1 The particulars detailed in 1.11 are to be markedon all materials which have been accepted.

6.2.4 For plate supplied from coil, the chemical analysismay be transposed from the certificate of the coil manufactureonto the re-processor’s certificate.

6.3 Heat treatment

6.3.1 All materials are to be supplied in a conditioncomplying with the requirements given in Table 3.6.2.


6.4.1 For plates, tensile test specimens are to be takenfrom both ends of each piece. A piece is to be regarded asthe rolled product from a single slab or from a single ingot ifthis is rolled directly into plates.

6.4.2 For strips, tensile test specimens are to be takenfrom both ends of each coil.



Chapter 3Section 6

Grade of steel C Si Mn Ni P S Residual elements Aluminium

11/2 Ni0,18

0,30 – 1,50 1,30 – 1,70max.

Cr 0,25 max.

Total 0,020%

31/2 Ni0,15

3,20 – 3,800,025 0,020

Cu 0,35 max.

min.

max. max. max.Mo 0,08 max.0,10 – 0,35

Total 0,60 max.5Ni0,12 0,30 – 0,90

4,70 – 5,30Acid soluble

max. 0,015% min.

9Ni0,10

8,50 – 10,0max.

Table 3.6.1 Chemical compositions of nickel alloy steels

Grade Plates Sections and bars

LT – AHN TM

LT – DH Any

LT – EH Normalised (see Note)T.M.C.P.

LT – FH Quenched and tempered N TM

11/2 NiNormalised (see Note)

31/2 Ni Normalised and temperedQuenched and tempered

5Ni

9Ni Double normalised and temperedQuenched and tempered

NOTEWhere the term ‘Normalised’ is used it does not include normalising rolling.

Table 3.6.2 Supply conditions




Chapter 3Section 6

Min

imum

des

ign

tem

pera

ture

( °C

)

–165

–105

–90

–60

–45

25Thickness in mm

–75

–90

40

1 Ni

3 Ni

5 Ni

9 Ni

2665/21

12

12

–165

Fig. 3.6.2Minimum design temperatures for nickel grades

Yield Tensile ElongationGrade of stress strength on 5,65 So

steel N/mm2 N/mm2 % min.min.

27S 265 400 – 530 2232 315 440 – 590 22

LT – AH 36 355 490 – 620 21 040 390 510 – 650 20

27S 265 400 – 530 2232 315 440 – 590 22

LT – DH 36 355 490 – 620 21 –2040 390 510 – 650 20

27S 265 400 – 530 2232 315 440 – 590 22

LT – EH 36 355 490 – 620 21 –4040 390 510 – 650 20

27S 265 400 – 530 2232 315 440 – 590 22

LT – FH 36 355 490 – 620 21 –6040 390 510 – 650 20

11/2 Ni 275 490 – 640 22 –65

31/2 Ni 285 450 – 610 21 –95

5Ni 390 540 – 740 21 –110

9Ni 490 640 – 790 18 –196

NOTES1. These requirements are applicable to products not exceeding 40 mm in thickness. The requirements for thicker products are subject

to agreement.2. The minimum design temperatures at which plates of different thicknesses in the above grades may be used are given in Fig. 3.6.1 and

Fig. 3.6.2. Consideration will be given to the use of thicknesses greater than those in the Tables or to the use of design temperaturesbelow –165°C.

3. Impact tests are not required on thicknesses less than 6 mm.

Charpy V-notch impact tests (see Note 3)

Test temp. Impact °C energy

Table 3.6.3 Mechanical properties for acceptance purposes (see Note 1)

Plates –transverse tests

Averageenergy 27 J min

Sections and bars –longitudinal tests

Averageenergy 41 J min

–55

–35

–15

0

20 25 40

–40

–20

LT– AH

LT– DH

LT– EH

LT– FH

Thickness in mm

Min

imum

des

ign

tem

pera

ture

( °C

)

2665/27

0

Fig. 3.6.1Minimum design temperatures for

carbon-manganese grades

7.1.4 Duplex stainless steels are suitable for applicationswhere the lowest design temperature is above 0°C. Anyrequirement to use duplex stainless steels below 0°C will besubject to special consideration.

7.1.5 Duplex stainless steels are also suitable for serviceat temperatures up to 300°C, and for such applications theproposed specification should include, in addition to therequirements of 7.1.6, a minimum value for 0,2 per cent proofstress at the design temperature.

7.1.6 A specification giving details of the chemicalcomposition, heat treatment and mechanical properties,including, for the austenitic grades, both the 0,2 and 1,0 percent proof stresses, is to be submitted for consideration andapproval.


7.2.1 The chemical composition of ladle samples is tocomply with the requirements given in Table 3.7.1.

7.2.2 Consideration will be given to the use of steelswhose compositions are outside the scope of Table 3.7.1.

7.3 Heat treatment

7.3.1 All materials are to be supplied in the solutiontreated condition.


6.6.1 At least two copies of each test certificate are to beprovided. They are to be of the type and give the informationdetailed in 1.12 together with general details of the heat treatment. As a minimum, chemical composition is to includethe contents of any grain refining elements used and of theresidual elements as detailed in Tables 3.3.2 or 3.6.1.

■ Section 7Austenitic and duplex stainlesssteels

7.1 Scope

7.1.1 Provision is made in this Section for rolled products in austenitic and duplex (austenite plus ferrite) stainless steels intended for use in the construction of cargotanks, storage tanks and process pressure vessels for chemicals and liquefied gases.

7.1.2 Austenitic stainless steels are suitable for applications where the lowest design temperature is not lowerthan –165°C.

7.1.3 Austenitic stainless steels are also suitable forservice at elevated temperatures, and for such applicationsthe proposed specification should contain, in addition to therequirements of 7.1.6, minimum values for 0,2 and 1,0 percent proof stresses at the design temperature.




Chemical composition % (see Note)Type and grade

of steel C Si Mn P S Cr Ni Mo N Other

Austenitic

304 L 17,0—20,0 8,0—13,0 — 0,10 —

304 LN 17,0—20,0 8,0—12,0 — 0,10—0,22 —

316 L 0,03 16,0—18,5 10,0—15,0 2,0—3,0 0,10 —

316 LN 1,0 2,0 0,045 0,03 16,0—18,5 10,0—14,5 2,0—3,0 0,10—0,22 —

317 L 18,0—20,0 11,0—15,0 3,0—4,0 0,10 —

317 LN 18,0—20,0 12,5—15,0 3,0—4,0 0,10—0,22 —

321 0,08 17,0—19,0 9,0—12,0 — 0,10 5 x C ≤ Ti ≤ 0,7

347 0,08 17,0—19,0 9,0—13,0 — 0,10 10 x C ≤ Nb ≤ 1,0

Duplex

UNS S 31803 0,03 1,0 2,0 0,03 0,02 21,0—23,0 4,5—6,5 2,5—3,5 0,08—0,20 —

UNS S 32750 0,03 0,80 1,2 0,035 0,02 24,0—26,0 6,0—8,0 3,0—5,0 0,24—0,32 Cu 0,50 max.

NOTEAll figures are a maximum value except where a range is shown.


7.6.4 Wherever practical, exposed cut edges should beavoided. However, where any such edges are to remain afterfabrication is completed, it is to be shown by an appropriate test,that the corrosion resistance is adequate for the cargoesexpected to be encountered.

7.7 Clad plates

7.7.1 Carbon or carbon-manganese steel plates, clad onone or both surfaces with a suitable grade of austenitic or duplex stainless steel, may be used for the construction ofcargo or storage tanks for chemicals.

7.7.2 The carbon or carbon-manganese steel base platesare to comply with the requirements of Section 4, and theaustenitic cladding material generally with the requirements ofthis Section.

7.7.3 The process of manufacture is to be speciallyapproved and may be either by roll cladding, or by explosivebonding.

7.7.4 Where the use of clad materials is proposed, thematerial specification is to be submitted for consideration,together with details of the extent, and the acceptance standards for non-destructive examination.


7.8.1 The particulars detailed in 1.11 are to be marked on allmaterials which have been accepted.


7.9.1 At least two copies of each test certificate are to beprovided. They are to be of the type and give the informationdetailed in 1.12 and, where applicable, the results obtained fromintercrystalline corrosion tests, and, additionally, are to state thespecified maximum carbon equivalent. As a minimum, chemicalcomposition is to include the contents of any grain refiningelements used and of the residual elements, as detailed in Table3.7.1.


7.4.1 Tensile test specimens are to be taken in accordancewith the appropriate requirements of 4.4 and 6.4.1.

7.4.2 For the duplex grades, one set of three Charpy V-notch impact test specimens machined from the longitudinaldirection for each tensile test is to be tested at –20°C. The aver-age energy value of the three specimens is to be not less than41 Joules.

7.4.3 Unless otherwise agreed, impact tests are notrequired from the austenitic grades of steel given in this Section.

7.4.4 Where standard subsidiary Charpy V-notch testspecimens are necessary, see Ch 2,3.2.4.

7.4.5 The results of all tensile tests are to comply with therequirements of Table 3.7.2 or the approved specification.

7.5 Metallographic examination for sigma phase

7.5.1 The microstructure of all grades listed in Table 3.7.1are to be examined metallographically at x400 magnification todemonstrate that sigma phase remains below 0,1 per cent ofthe observable area at a frequency of one per heat.

7.6 Intergranular corrosion tests

7.6.1 For certain specific applications such as storagetanks for chemicals, it may be necessary to demonstrate thatthe material used is not susceptible to intergranular corrosionresulting from grain boundary precipitation of chromium-richcarbides.

7.6.2 When required, one test of this type is to be carriedout for each tensile test. The material for the test is to be takenadjacent to that for the tensile test.

7.6.3 Unless otherwise agreed or required for a particularchemical cargo, the testing procedure is to be as given in 7.6.4,see Ch 2,9.




Chapter 3Section 7


Type and grade of steel

Austenitic304L

304LN316L

316LN317L

317LN321347

DuplexUNS S 31803UNS S 32750

0,2% Proof stress(N/mm2) minimum

170205170205205240205205

450550

1% Proof stress(N/mm2) minimum

210245210245245280245245

——

Tensile strength(N/mm2) minimum

485515485515515550515515

620795

Elongation on 5,65 So% minimum

4040404040404040

2515

■ Section 8Plates with specified throughthickness properties

8.1 Scope

8.1.1 Provision is made in this Section for ‘Z’ grade plateand wide flat material with improved ductility in the throughthickness or ‘Z’ direction, see Fig. 3.8.1. The use of this material is recommended for certain types of welded structures (see 1.2) in order to minimise the possibility oflamellar tearing either during fabrication or erection.

8.1.2 Through thickness properties are characterised byspecified values for reduction of area in a through thicknesstensile test.

8.1.3 Provision is made for two grades Z25 and Z35. Fornormal ship applications the Z25 grade is applicable, whilstthe Z35 grade is for more severe applications.

8.1.4 This ‘Z’ grade material is to comply with therequirements of Sections 2, 3, 4, 5 and 6 as appropriate, andthe additional requirements of this Section.

8.1.5 The test procedure detailed in this Section may alsobe used to demonstrate that no unacceptable amount ofbanding of any detrimental phase, such as sigma is present,see 7.5.

8.2 Manufacture

8.2.1 All plates and wide flats are to be manufactured atworks, which have been approved by LR for this quality ofmaterial.

8.2.2 It is recommended that the steel should be efficiently vacuum de-gassed. The sulphur content is not toexceed 0,008 per cent.

8.2.3 Consideration will be given to proposals for alternative methods of improving through thickness properties.

8.3 Test material

8.3.1 Unless otherwise agreed, through thickness tensiletests are only required for plate materials where the thicknessexceeds 15 mm for carbon and alloy steels, or 10 mm in thecase of austenitic and duplex stainless steels.

8.3.2 For plates and wide flats, one test sample is to betaken close to the longitudinal centreline from one end of eachrolled piece representing the batch, see Table 3.8.1 and Fig. 3.8.2. The test sample must be large enough to accom-modate the preparation of 6 specimens. 3 test specimens areto be prepared while the rest of the sample remains for possi-ble retest.

8.3.3 The dimensions of the test specimens are to be inaccordance with Ch 2,2.1.12.

8.3.4 Alternatively, test sampling may be carried out inaccordance with an accepted National or International Standard.




Chapter 3Section 8

Through thickness direction 'Z'

Principal rolling (longitudinal)direction 'L'

Transverse direction 'T'

Fig. 3.8.1 Schematic of testing directions

Table 3.8.1 Batch size dependent on product andsulphur content

Product

Plates

Wide flats of nominal thickness ≤ 25 mm

Wide flats of nominal thickness > 25 mm

S > 0,005%

Each piece (parentplate)

Maximum 10 t ofproducts of thesame cast, thickness and heattreatment


S < 0,005%




Principal rolling direction

Central line of product

Test sample

Test specimens

Fig. 3.8.2Plate and wide flat sampling position


8.6.1 Products which comply with the requirements ofthis Section are to have the notation Z25 or Z35 added to thesteel grade designation.


8.7.1 The following information is required to be includedon the certificate in addition to the appropriate steel graderequirements:(a) Through thickness reduction in area (%), individual

results and average.(b) Steel grade with Z25 or Z35 notation.

8.7.2 Steel grade requirements are to comply withSections 1 to 7.

■ Section 9Bars for welded chain cables

9.1 Scope

9.1.1 Provision is made in this Section for rolled steelbars intended for the manufacture of three Grades (U1, U2and U3) of stud link chain cable for the anchoring and mooring of ships and five Grades (R3, R3S, R4, R4S and R5)of offshore mooring cable.

9.1.2 For the ship grades, U1, U2 and U3, approval willpermit the supply of bars of the appropriate grades and sizeto any chain cable manufacturer.

9.1.3 For the offshore grades, R3, R3S, R4, R4S and R5,approval is confined to bar to be supplied to a nominatedchain manufacturer and will be given only after successfultesting of a completed chain. Separate approvals are requiredif bar is to be supplied to more than one cable manufacturer.Approval of a higher grade does not cover approval of a lowergrade, as all grades must be individually approved.

9.1.4 For all grades, approval is normally given for diameters of bars no greater than those of the bars used inprocedure tests.

9.2 Manufacture

9.2.1 All grades of bar material are to be made from killedsteel, and all grades of bar material except for Grade U1 chaincables are to be fine grained. For Grades R4S and R5 theaustenite grain size is to be 6 or finer, in accordance withASTM E112.

9.2.2 The bars are to be made to a specificationapproved by LR which should include the manufacturingprocedure, deoxidation practice, heat treatment and mechan-ical properties.


8.4.1 The three through thickness tensile test specimensare to be tested at ambient temperature, and for acceptanceare to give a minimum average reduction of area value of notless than that shown in Table 3.8.2. Only one individual valuemay be below the minimum average, but should not be lessthan the minimum individual value shown for the appropriategrade.

8.4.2 If the average value fails to comply with 8.4.1, threeadditional tests may be made on specimens from the sametest sample. The results of these tests are to be added tothose previously obtained to form a new average, which foracceptance is to be not less than 25 per cent for grade Z25or 35 per cent for grade Z35. No individual results in the re-test shall be below 25 per cent for grade Z25 or 35 percent for grade Z35, see Fig. 3.8.3.

8.4.3 Where batch testing is permitted, and failure afterre-test occurs, the tested piece is to be rejected. Eachremaining piece in the batch may be individually tested andaccepted, based on satisfactory results.

8.4.4 If the fracture of a test specimen occurs in the weldor in the heat affected zone the test is to be regarded asinvalid and is to be repeated on a new test specimen.

8.5 Non-destructive examination

8.5.1 All ‘Z’ grade plates are to be ultrasonically tested inthe final supply condition with a probe frequency of 3-5 MHz.The testing is to be performed in accordance with and incompliance with either EN 10160 Level S1/E1 or ASTM A 578Level C.



Table 3.8.2 Reduction of area acceptance values

Grade

Minimum average

Minimum individual

Z25

25%

15%

Z35

35%

25%

= Individual result = average result

Acceptableresult

Acceptablere-test

Result wherere-test ispermitted

Minimumaverage

Minimumindividual

Fig. 3.8.3Diagram showing acceptance/rejection

and re-test criteria


9.5 Embrittlement tests

9.5.1 For Grades R3, R3S, R4, R4S and R5 the barmanufacturer is to provide evidence that the material is notsusceptible to strain ageing, or to temper brittleness underthe conditions of manufacture of the chain. The results of therelevant tests are to be reported to LR at the approval stage.Approval will be restricted to the specified steel compositionand if later this is altered then re-approval will be required.Temper brittleness testing may be waived, if the chain is to bequenched after tempering.

9.5.2 Each heat of steel bars of grades R3S, R4, R4S andR5 is to be tested for hydrogen embrittlement (see Ch 2,5.3).In the case of continuous casting, test samples representingboth the beginning and the end of the heat are to be taken. Inthe case of ingot casting, test samples representing two different ingots are to be taken.

9.5.3 Each sample is to be heat treated in a manner simulating the heat treatment of the finished chain. From eachsample, two specimens are to be prepared from the mid-diameter of the bar and tested in accordance with Ch 2,5.3.

9.5.4 The ratio Z1/Z2 is to be greater than or equal to0,85, where Z1 is the reduction in area without baking and Z2the reduction in area after baking.

9.5.5 If the requirement is not met, the material is to besubjected to a hydrogen degassing treatment which is subjectto approval by LR. Further tests are to be performed afterdegassing.


9.6.1 Bars of the same nominal diameter are to be presented for test in batches of 50 tonnes or fraction thereoffrom the same cast. A suitable length from one bar in eachbatch is to be selected for test purposes. Test pieces are tobe taken from the positions as shown in Fig. 3.9.1.

9.6.2 For all grades, one tensile test is to be taken fromeach sample length selected. Additionally, for Grades U3, R3,R3S, R4, R4S and R5 material, one set of three Charpy V-notch impact test specimens is to be prepared. Impacttests are also required for Grade U2 when the chain is to besupplied in as-welded condition.

9.2.3 The rolling reduction ratio of bars for Grades R3,R3S, R4, R4S and R5 must be at least 5:1.


9.3.1 For Grades U1, U2 and U3 the chemical composi-tion should be generally within the limits given in Table 3.9.1.

9.3.2 For Grades R3, R3S, R4, R4S and R5 the chemicalcomposition is to comply with an approved specification, see9.2.2.

9.3.3 For Grades R4, R4S and R5 chain cable the steelshould contain a minimum of 0,2 per cent molybdenum. Thereported composition is to include the contents of antimony,arsenic, tin, copper, nitrogen, aluminium and titanium.

9.3.4 For Grades R4S and R5 the steel used must bevacuum degassed.

9.4 Heat treatment

9.4.1 Unless stipulated otherwise, the bars are to besupplied in the as-rolled condition, but the supplier is to beadvised by the chain manufacturer of the heat treatment tobe used for the completed chain in order that the mechanicaltest specimens may be tested in the condition of heat treat-ment used for the chain.

9.4.2 For Grades U1 and U2, the samples selected fromeach batch may be tested either in the as-rolled condition, orafter heat treatment where the chain is to be used in the heattreated condition, in full cross-section and in a manner simu-lating the heat treatment applied to the finished cable.

9.4.3 For Grades U3, R3, R3S, R4, R4S and R5 thesample is to be tested after heat treatment as detailed in9.4.2.




Chapter 3Section 9

Chemical composition %

Grade CSi Mn

P SAl

Nb V N Cr Cu Ni Momax. max. max. max. max. max. max. max. max. max.

U1 0,20 0,15–0,35 0,40 min. 0,04 0,04 – – – – – – – –

U2 0,24 0,15–0,55 1,60 max. 0,035 0,035 0,02 min. – – – – – – –see Note 1

U3 0,33 0,15–0,35 1,90 max. 0,04 0,04 0,065 max. 0,05 0,10 0,015 0,25 0,35 0,40 0,08see Note 2 see Note 2 see Note 2

NOTES1. Aluminium may be partly replaced by other grain refining elements.2. To obtain fine grain steel, at least one of these grain refining elements must be present in sufficient amount.

Table 3.9.1 Chemical composition of killed steel bars

9.6.4 Failure to meet the requirements will result in therejection of a batch of material, unless it is clearly attributed toimproper simulated heat treatment. This is to be confirmed tobe to the satisfaction of LR, and further heat treatment andtesting will be required prior to acceptance.

9.7 Structure and hardenability tests

9.7.1 For Grades R4S and R5, the following tests are tobe carried out on each heat:(a) Assessment and quantification of the level of non-metallic

micro inclusion. These must be acceptable for the finalproduct.

(b) Macro etching on a representative sample, in accor-dance with ASTM E381 or equivalent. This must be freefrom any injurious segregation or porosity.

(c) Jominy hardenability tests in accordance with ASTMA255 or equivalent.


9.8.1 The tolerances on diameter and ovality of the barare to be in accordance with Table 3.9.3.

9.6.3 The results of all tensile and, where applicable,impact tests are to be in accordance with the appropriaterequirements of Table 3.9.2.




Chapter 3Section 9

Charpy V-notch impact testsReduction

Yield stress Tensile strength Elongation of area Test Average Average energyGrade N/mm2 N/mm2 on 5,65 So % % temperature energy flash weld

minimum minimum minimum °C J Jminimum minimum

U1 – 370–490 25 — — — —

U2 295 490–690 22 — 0 27 —(see Note 1)

U3 410 690 minimum 17 40 0 60 —–20 35 —

(see Note 2)

R3 410 690 minimum 17 50 0 60 50(see Note 3) (see Note 3) –20 40 30

(see Note 2)

R3S 490 770 minimum 15 50 0 65 53(see Note 3) (see Note 3) –20 45 33

(see Note 2)

R4 580 860 minimum 12 50 –20 50 36(see Note 3) (see Note 3)

Grade R4S 700 960 minimum 12 50 –20 56 40(see Note 4) (see Note 3) (see Note 3)

Grade R5 760 1000 minimum 12 50 –20 58 42(see Note 4) (see Note 3) (see Note 3)

NOTES1. Impact tests may be waived when the chain cable is to be supplied in one of the heat treated conditions given in Table 10.2.3.2. Testing may be carried out at either 0°C or –20°C, at the option of LR.3. The ratio of yield strength to tensile strength should not exceed 0,92.4. The maximum hardness for R4S is to be HB330, and for R5 is to be HB340.

Table 3.9.2 Mechanical properties

r/3

r/3

Specimen for notched barimpact test

Testspecimen

r = specimen radius

Fig. 3.9.1 Sampling of steel bars


9.11.1 Each consignment of bars is to be accompanied bya certificate of a type and in accordance with 1.12, but withthe addition of the grade of chain cable, the rolling reductionratio, the results of the hydrogen embrittlement,micro inclusion,macro etch and hardenability tests, where required by eachgrade.

■ Section 10High strength quenched and tempered steels for welded structures

10.1 Scope

10.1.1 Provision is made in this Section for weldable highstrength quenched and tempered steel plates and wide flatsup to 70 mm thick. However, special consideration will begiven to thicknesses up to 50 mm supplied in the TM rolledcondition.

10.1.2 Plates and wide flats exceeding 70 mm in thicknessas well as other product forms may also be supplied in accordance with the requirements of this Section, providedthat the prior agreement of LR is obtained.

10.1.3 The steels may be supplied in six strength levelswith minimum yield stresses of 420, 460, 500, 550, 620 and690 N/mm2 respectively.

10.1.4 Each strength level is sub-divided into four gradesAH, DH, EH and FH, differing essentially in the required levelsof notch toughness.

10.1.5 For the designation to fully identify a steel and itsproperties, the appropriate grade letter should precede thestrength level number, e.g., EH 42.

10.1.6 Steels differing in strength level, mechanical properties and chemical composition from those detailed inthis Section may be supplied, subject to special approval fromLR. Such steels are to have the letter ‘S’ after the agreedidentification mark.


10.2.1 The steels are to be fully killed and fine graintreated.

10.2.2 The chemical composition is to comply with therequirements of the approved manufacturing specification andthe limits set in Table 3.10.1.


9.9.1 For the grades U1, U2 and U3 all bars are to befree from internal and surface defects that might impair properworkability, use and strength. Subject to agreement by theSurveyor, surface defects may be removed by grindingprovided the acceptable tolerances are not exceeded.

9.9.2 For the R3, R3S, R4, R4S and R5 grades all barsare to be inspected by a magnetic particle or eddy currentmethod, and are also to be subjected to ultrasonicexamination.

9.9.3 All non-destructive examination is to be carried outin accordance with approved procedures, in accordance withCh 1,5.

9.9.4 All non-destructive examination operators are to bequalified in the method of non-destructive examination, to aminimum of Level II in accordance with a recognised standard.

9.9.5 The bars are to be free from pipes, cracks, flakes,and injurious surface defects such as seams, laps, and rolled-in mill scale. Longitudinal discontinuities may be removed byblending to a smooth contour provided that their depth is notgreater than 1 per cent of the bar diameter, and that therequired diameter tolerances are not compromised. Thecontour radiuses are to be a minimum of four times the excavation depth.

9.9.6 The frequency of non-destructive testing may bereduced at the discretion of LR, provided statistical evidenceis available that the required quality is achieved consistently.

9.10 Identification

9.10.1 Each bar is to be identified in accordance with 1.10and, in addition, is to be marked with the appropriate grade ofchain cable.





Table 3.9.3 Dimensional tolerance of bar stock

Nominal Tolerance on Tolerance ondiameter diameter roundness

mm mm (dmax – dmin)mm

≤20 –0/+1,0 0,60

>20 ≤25 –0/+1,0 0,60

>26 ≤35 –0/+1,2 0,80

>36 ≤50 –0/+1,6 1,10

>51 ≤80 –0/+2,0 1,50

>81 ≤100 –0/+2,6 1,95

>101 ≤120 –0/+3,0 2,25

>121 ≤160 –0/+4,0 3,00

>161 ≤210 –0/+5,0 4,00

10.2.3 The cold cracking susceptibility, Pcm, may be usedas an alternative to the carbon equivalent for evaluating weldability. It is to be calculated from the ladle analysis usingthe following formula:

Pcm = C + + + + + + 5B

The maximum allowable Pcm is to be agreed with LR and is tobe included in the approved manufacturing specification.

10.3 Mechanical properties

10.3.1 At least one tensile test piece and one set of threeCharpy V-notch impact tests specimens are to be taken fromeach piece as heat treated.

10.3.2 For continuously heat treated products, one tensiletest piece and a set of three impact test specimens are to betaken from each plate as heat treated.

Si30

Mn + Cr + Cu20

Ni60

Mo15

V10


Chapter 3Section 10


Grade AH DH EH FH

Carbon % max 0,21 0,20 0,18

Manganese % max 1,70 1,70 1,60

Silicon % max 0,55 0,55 0,55

Phosphorus % max 0,035 0,030 0,025

Sulphur % max 0,035 0,030 0,025

Nitrogen % max 0,020 0,020 0,020

Grain refining elements(see Note 1)

Aluminium (acid soluble)% min (see Note 2) 0,015

Niobium % 0,02—0,05

Vanadium % 0,03—0,10

Titanium % max 0,02

Total (Nb + V + Ti) % max 0,12

NOTES1. The steel is to contain aluminium, niobium, vanadium or other

suitable grain refining elements, either singly or in any combi-nation. When used singly, the content is to be within the limitsgiven in the Table. When used in combination, these limits arenot applicable but the proportions of the grain refining ele-ments are to be in accordance with the approvedmanufacturing specification.

2. The total aluminium content may be determined instead of theacid soluble content. In such cases the total aluminium con-tent is not to be less than 0,020%.

3. Alloying elements and residual elements other than those listedin the Table (e.g., Ni, Cr, Cu, Mo and B) are to be included inthe approved manufacturing specification.

Table 3.10.1 Chemical composition 10.3.3 For plates and wide flats with widths exceeding600 mm, the tensile and impact test specimens are to betaken with their axes transverse to the final direction of rolling.For other products, the impact test specimens are to be takenin the longitudinal direction but the tensile test specimens maybe taken in either the longitudinal or transverse direction asagreed with LR.

10.3.4 The results of all tests are to comply with the appropriate requirements of Table 3.10.2.

10.3.5 Where standard subsidiary impact test specimensare necessary, see Ch 2,3.2.4.


10.4.1 The particulars detailed in 1.11 are to be marked oneach piece which has been accepted and, for ease of recognition, are to be encircled or otherwise marked with paint.


10.5.1 At least two copies of each test certificate are tobe provided. They are to be of the type and give the informa-tion detailed in 1.12 and, additionally, are to state the specifiedmaximum carbon equivalent. As a minimum, chemical compo-sition is to include the contents of any grain refining elementsused and of the residual elements as detailed in Table 3.10.1.


Chapter 3Section 10


Elongation on Charpy V-notch impact tests (see Note 4)

Yield stressTensile strength

5,65 SoGrade N/mm2

N/mm2 % minimum Test Average energymin. (see Note 2) temperature J minimum

(see Note 1)Transverse Longitudinal °C Transverse Longitudinal

AH 42 0DH 42 420 530 – 680 18 20 –20 28 42EH 42 –40FH 42 –60

AH 46 0DH 46 460 570 – 720 17 19 –20 31 46EH 46 –40FH 46 –60

AH 50 0DH 50 500 610 – 770 16 18 –20 33 50EH 50 –40FH 50 –60

AH 55 0DH 55 550 670 – 830 16 18 –20 37 55EH 55 –40FH 55 –60

AH 62 0DH 62 620 720 – 890 15 17 –20 41 62EH 62 –40FH 62 –60

AH 69 0DH 69 690 770 – 940 14 16 –20 46 69EH 69 –40FH 69 –60

NOTES1. Where a distinct yield stress indication is not obtainable during tensile testing the 0,2% proof stress is applicable.2. For full thickness tensile test specimens with a width of 25 mm and a gauge length of 200 mm (see Fig. 2.2.4 in Chapter 2) the minimum

elongation is to be:

These values apply to transverse specimens. Where the use of longitudinal specimens has been agreed, the values are to be increased by2%.

3. The ratio of yield strength to tensile strength should not exceed 0,94.4. Impact tests are not required on thicknesses less than 6 mm.


Thickness mm >10 >15 >20 >25 >40 >50≤10 ≤15 ≤20 ≤25 ≤40 ≤50 ≤70

Strength levels42 11 13 14 15 16 17 18

Elongation 46 11 12 13 14 15 16 17% 50 and 55 10 11 12 13 14 16 16

62 9 11 12 12 13 14 1569 9 10 11 11 12 13 14

Steel Castings

Section


2 Castings for ship and other structuralapplications

3 Castings for machinery construction

4 Castings for crankshafts

5 Castings for propellers

6 Castings for boilers, pressure vessels andpiping systems

7 Ferritic steel castings for low temperatureservice

8 Stainless steel castings

9 Steel castings for container corner fittings


1.1 Scope

1.1.1 This Section gives the general requirements forsteel castings intended for use in the construction of ships,other marine structures, machinery, boilers, pressure vesselsand piping systems.

1.1.2 Where required by the relevant Rules dealing withdesign and construction, castings are to be manufacturedand tested in accordance with Chapters 1 and 2, togetherwith the general requirements given in this Section and theappropriate specific requirements given in Sections 2 to 9.

1.1.3 As an alternative to 1.1.2, castings which complywith National or proprietary specifications may be acceptedprovided that these specifications give reasonable equiva-lence to the requirements of this Chapter or alternatively areapproved for a specific application. Generally, survey and certification are to be carried out in accordance with therequirements of Chapter 1.

1.1.4 Where small castings are produced in large quantities,or where castings of the same type are produced in regularquantities, alternative survey procedures, in accordance withCh 1,2.4 may be adopted.

1.2 Manufacture

1.2.1 Castings are to be made at foundries approved byLR. The steel used is to be manufactured by a processapproved by Lloyd’s Register (hereinafter referred to as ‘LR’).

Chapter 4Section 1


Steel Castings

1.2.2 All flame cutting, scarfing or arc-air gouging toremove surplus metal is to be undertaken in accordance withrecognised good practice and is to be carried out before thefinal heat treatment. Preheating is to be employed wherenecessitated by the chemical composition and/or thickness ofthe casting. The affected areas are to be either machined orground smooth for a depth of about 2 mm unless it has beenshown that the material has not been damaged by the cuttingprocess. Special examination will be required to find any cracking in way of the cut surfaces.

1.2.3 Where two or more castings are joined by weldingto form a composite item, details of the proposed weldingprocedure are to be submitted for approval. Welding approvalprocedure tests will be required, see also the requirements of 1.9.

1.3 Quality of castings

1.3.1 All castings are to be free from surface or internaldefects which would be prejudicial to their proper applicationin service. The surface finish is to be in accordance with goodpractice and any specific requirements of the approved specification.

1.3.2 The surfaces are not to be hammered, peened ortreated in any way which may obscure defects.

1.3.3 The locations of all chaplets are to be noted and tobe subject to close visual inspection (and when necessary ultrasonic examination) to ensure complete fusion.


1.4.1 All castings are to be made from killed steel. Thechemical composition of the ladle sample is to be within thelimits given in the relevant Section of this Chapter. Wheregeneral overall limits are specified, the chemical compositionis to be appropriate for the type of steel, dimensions andrequired mechanical properties of the castings.

1.4.2 Except where otherwise specified, suitable grainrefining elements may be used at the discretion of the manufacturer. The content of such elements is to be reportedin the ladle analysis.

1.5 Heat treatment

1.5.1 All castings are to be heat treated in accordancewith the requirements given in the relevant Section of thisChapter.


Steel Castings

1.5.2 Heat treatment is to be carried out in a properlyconstructed furnace which is efficiently maintained and hasadequate means of temperature control. The furnace dimensions are to be such as to allow the steel castings to beuniformly heated to the necessary temperature. Sufficient thermocouples are to be connected to the steel castings toshow that their temperature is adequately uniform and thetemperatures are to be recorded throughout the heat treatment.Alternative procedures are to be approved by LR, Materials andNDE department. Copies of these records are to be presentedto the Surveyor together with a sketch showing the positions atwhich the temperature measurements were carried out. Therecords are to identify the furnace that was used and give detailsof the individual steel castings, the heat treatment temperatureand time at temperature and the date. The Surveyor is to examine the charts and confirm the details on the certificate. Inthe case of very large components which require heat treatment,alternative methods will be specially considered.

1.5.3 If a casting is locally reheated, or any straighteningoperation is performed after the final heat treatment, a subsequent stress relieving heat treatment may be requiredin order to avoid the possibility of harmful residual stresses.

1.6 Test material and test specimens

1.6.1 Test material sufficient for the tests specified inSections 2 to 9 and for possible re-test purposes is to beprovided for each casting. The test samples are to be eitherintegrally cast or gated to the casting and are to have a thickness of not less than 30 mm.

1.6.2 The test samples are not to be detached from thecasting until the heat treatment specified in 1.5.1 has beencompleted and they have been properly identified.

1.6.3 As an alternative to 1.6.1 and 1.6.2, where anumber of small castings of about the same size, each ofwhich is under 1000 kg in mass, are made from one cast andheat treated in the same furnace charge, a batch testingprocedure may be adopted, using separately cast testsamples of suitable dimensions. The test samples are to beproperly identified and heat treated together with the castingswhich they represent. At least one test sample is to beprovided for each batch of castings.

1.6.4 The test specimens are to be prepared in accor-dance with the requirements of Chapter 2. Tensile testspecimens are to have a cross-sectional area of not less than150 mm2.

1.6.5 Re-test procedures are to be in accordance withCh 2,1.4.


1.7.1 This Section gives the general requirements fornon-destructive examination of steel castings. As an alterna-tive, castings may be examined in accordance with a NationalSpecification, provided it gives reasonable equivalence tothese Rules.

1.7.2 All castings are to be cleaned and adequatelyprepared for inspection. Suitable methods include pickling,caustic cleaning, wire brushing, local grinding, shot or sandblasting.

1.7.3 The surfaces are not to be hammered, peened ortreated in any way which may obscure defects.

1.7.4 Unless otherwise agreed, the accuracy and verification of dimensions are the responsibility of the manu-facturer.

1.7.5 All castings are to be presented to the Surveyor forvisual examination. Where applicable, this is to include theexamination of internal surfaces. Castings are to be subject tomagnetic particle examination or dye penetrant inspection (foraustenitic stainless steel castings, see Section 8) in accordance with 1.7.9, unless more specific requirements for non-destructive examination are included in subsequentSections of this Chapter, other parts of the Rules or the agreedspecification.

1.7.6 Where specified or required by the Rules non-destructive examination is to be carried out beforeacceptance. All tests are to be in accordance with the require-ments of Ch 1,5.

1.7.7 The manufacturer is to provide the Surveyor with asigned report confirming that non-destructive examination hasbeen carried out and that such inspection has not revealedany significant defects.

1.7.8 Where magnetic particle examination is specified orrequired, this is to be carried out using a suspension ofmagnetic particles in a suitable fluid. The dry powder methodis not acceptable for the final inspection. Prods are notpermitted on finished machined surfaces.

1.7.9 Where required, magnetic particle or dye penetranttesting is to be carried out by the manufacturer wheneverappropriate and also when the castings are in the finishedcondition. The tests are to be made in the presence of theSurveyor unless otherwise specially agreed. The castings areto be examined in the following areas:(a) At all accessible fillets and changes of section.(b) At positions where surplus metal has been removed by

flame cutting, scarfing or arc-air gouging.(c) In way of fabrication weld preparations, for a distance

not less than 50 mm form the edge.(d) In way of welds. (e) In way of chaplets.(f) At other positions agreed with the Surveyor to include

areas which may be subjected to high stress in service.

1.7.10 Where required by subsequent Sections or by theagreed specification, ultrasonic examination is to be carriedout by the manufacturer, but Surveyors may request to bepresent in order to verify that the examination is carried out inaccordance with the agreed procedure. This examination isto be carried out in the following areas:(a) At positions which may be subjected to high stresses in

service, as agreed with the Surveyor.(b) In way of fabrication weld preparations, for a distance

not less than 50 mm form the edge.


Chapter 4Section 1

LLOYD’S REGISTER2

Steel Castings

(c) At positions where subsequent machining may exposefilamentary shrinkage or other defects (e.g., bolt holes,bearing bores).

(d) In way of welding.(e) In way of riser positions.(f) At positions where experience shows that significant

internal defects may occur: these are to be agreed between the manufacturer and the Surveyor.

1.7.11 Radiographic examination, where required, is to becarried out by the manufacturer in areas generally as indicatedfor ultrasonic examination in 1.7.10. All radiographs are to besubmitted to the Surveyor for examination and acceptance.The radiographic technique and acceptance standards are tobe to the satisfaction of the Surveyor and in accordance withany requirements of the approved specification.

1.7.12 In the event of any casting proving to be defectiveduring subsequent machining or testing it is to be rejectednotwithstanding any previous certification.

1.7.13 The general acceptance criteria given in 2.5.2 areto be applied where no specific acceptance criteria are statedin the subsequent Sections of this Chapter.

1.8 Pressure testing

1.8.1 Where required by the relevant Rules, castings areto be pressure tested in the final machined condition before finalacceptance. These tests are to be carried out in the presenceof the Surveyors and are to be to their satisfaction.

1.9 Rectification and dressing of castings

1.9.1 When unacceptable defects are found in a casting,these are to be removed by machining or chipping. Flame-scarfing or arc-air gouging may also be used provided thatpreheating is employed when necessary and that the surfacesof the resulting excavation are subsequently ground smooth.Complete elimination of the defective material is to be provenby adequate non-destructive examination. Shallow grooves or excavations resulting from the removal of defects may, at thediscretion of the Surveyor, be accepted provided that they willcause no appreciable reduction in the strength of the castings and that they are suitably blended by grinding.Complete elimination of the defective material is to be verifiedby magnetic particle or dye penetrant testing.

1.9.2 Where flame scarfing or arc-air gouging is used, therequirements detailed in 1.2.2 are to apply.

1.9.3 Grinding wheels for use on austenitic stainlesssteels are to be of an iron-free type and shall have been usedonly on stainless steels.

1.9.4 All proposals to repair a defective casting by weldingare to be submitted to the Surveyor before this work iscommenced. The Surveyor is to satisfy himself that thenumber, position and size of the defects are such that thecasting can be effectively repaired.

1.9.5 A statement and/or sketch detailing the extent andposition of all welds is to be prepared by the manufacturer.Copies of these sketches are to be submitted to LR, andcopies are to be attached to the certificates for the castings.

1.9.6 All welding is to be carried out by an approvedwelder and in accordance with an approved welding procedure which includes the features referred to in 1.9.6 to1.9.13.

1.9.7 Where welding is required, a grain refining heattreatment is to be given to the whole casting prior to carryingout welding unless agreed otherwise with the Surveyor. Grainrefining heat treatment requires heating above the upper critical temperature.

1.9.8 Any excavations are to be of suitable shape toallow good access for welding and, after final preparation forwelding, are to be re-examined by suitable non-destructivetesting methods to ensure that all defective material has beeneliminated.

1.9.9 All castings in alloy steels other than austenitic andduplex stainless steels are to be suitably preheated prior towelding. Castings in carbon-manganese steels may also berequired to be preheated, depending on their chemicalcomposition, the dimensions, configuration and positions ofthe welds.

1.9.10 Welding is to be carried out under cover, in positionsfree from draughts and adverse weather conditions. As far aspossible, all welding is to be carried out in the downhand (flat)position.

1.9.11 The welding consumables used are to be of anappropriate composition, giving a weld deposit with mechanicalproperties similar and in no way inferior to those of the parentcastings. The use of low hydrogen type welding consumablesis preferred. Welding procedure tests are to be carried out bythe manufacturer to demonstrate that satisfactory mechanicalproperties can be obtained after heat treatment as detailed in1.9.12, and the results of these tests are to be presented tothe Surveyor.

1.9.12 After welding is completed, the castings are to begiven the heat treatment specified in Sections 2 to 9, or astress relieving heat treatment at a temperature of not lessthan 550°C. The type of heat treatment required will bedependent on the chemical composition of the casting andthe dimensions, positions and nature of the repairs.

1.9.13 Special consideration may be given to a local stressrelieving heat treatment. where both the welded area is smalland machining of the casting has reached an advancedstage, prior agreement is to be obtained from LR in writing.The welding procedure is to be such that residual stresses areminimised.


Chapter 4Section 1


Steel Castings

1.9.14 On completion of heat treatment, all welds andadjacent material are to be ground smooth and examined bymagnetic particle, or liquid penetrant testing, ultrasonic orradiographic examination. The Surveyor is to attend at theseinspections, to witness the results of magnetic particle orliquid penetrant examination and to examine any radiographs.Satisfactory results are to be obtained from all forms of non-destructive examination used.The acceptance criteria for theNDE of welds are to be in accordance with subsequentSections of this Chapter or where these do not exist, Tables 13.2.4 to 13.2.6 in Chapter 13, as appropriate.

1.9.15 Where no welding has been made on a casting, themanufacturer is to provide the Surveyor with a written statement that this is the case.

1.9.16 The foundry is to maintain full records detailing theweld procedure, heat treatment and the extent and location ofall welds made to each casting. These records are to be available for review by the Surveyor, and copies of individualrecords are to be supplied to the Surveyor on request.

1.9.17 For rectification of defective steel castings forcrankshafts, see 4.7.

1.10 Identification of castings

1.10.1 The manufacturer is to adopt a system of identifi-cation, which will enable all finished castings to be traced tothe original cast, and the Surveyor is to be given full facilitiesto trace the castings when required.

1.10.2 Before acceptance, all castings which have beentested and inspected with satisfactory results are to be clearlymarked by the manufacturer with the following particulars:(a) Identification number, cast number or other marking

which will enable the full history of the casting to betraced.

(b) Manufacturer’s name or trade mark.(c) LR or Lloyd’s Register and the abbreviated name of LR’s

local office.(d) Personal stamp of Surveyor responsible for inspection.(e) Test pressure, where applicable.(f) Date of final inspection.

1.10.3 Where small castings are manufactured in largenumbers, modified arrangements for identification may bespecially agreed with the Surveyor.


1.11.1 A LR certificate is to be issued, see Ch 1,3.1.

1.11.2 The manufacturer is to provide the Surveyor with awritten statement giving the following particulars for eachcasting or batch of castings which has been accepted:(a) Purchaser’s name and order number.(b) Description of castings and steel grade.(c) Identification number.(d) Steel-making process, cast number, chemical analysis

of ladle samples and, in the case of the Special grade(see Section 2), the chemical analysis of the product ortest bar.

(e) General details of heat treatment including the tempera-ture and time at temperature.

(f) Results of mechanical tests.(g) Test pressure, where applicable.

1.11.3 Where applicable, the manufacturer is to provide asigned report regarding non-destructive examination asrequired by 1.7.7 together with a statement and/or sketchdetailing the extent and position of all weld repairs made toeach casting as required by 1.9.5 or the statement detailedin 1.9.15.

■ Section 2Castings for ship and otherstructural applications

2.1 Scope

2.1.1 The requirements for carbon-manganese steelcastings, intended for ship and other structural applicationswhere the design and acceptance tests are related tomechanical properties at ambient temperature, are given inthis Section.

2.1.2 Provision is made for two quality grades, Normaland Special.

2.1.3 Where it is proposed to use carbon-manganesesteels of higher specified minimum tensile strength thanrequired by 2.4.3, or alloy steels, particulars of the chemicalcomposition, mechanical properties and heat treatment areto be submitted for approval.


2.2.1 The chemical composition of ladle samples is tocomply with Table 4.2.1.

2.2.2 For the Special grade, the product of the aluminiumand nitrogen contents is to comply with the following formula:

(% Al acid sol x % N) 105 ≤ 60

2.2.3 For the Special grade, a check chemical analysison the product or a test bar is mandatory. The check analysison the product or test bar is to comply with the requirementsof Table 4.2.1.



LLOYD’S REGISTER4

Steel Castings

2.3 Heat treatment

2.3.1 Castings are to be supplied:(a) fully annealed; or(b) normalised; or(c) normalised and tempered at a temperature of not less

than 550°C; or(d) quenched and tempered at a temperature of not less

than 550°C.

2.3.2 For larger castings where a coarse of microstruc-ture may be present in heavier thickness, a double austenisingheat treatment may be required to ensure adequate grainrefinement. A coarse microstructure will be indicated by anincreased attenuation of approxiamtely 30 dB/m at 2 MHzduring ultrasonic examination.

2.3.3 Following weld repair and or the attachment ofhandling brackets, all castings are to be subject to post weldheat treatment at a temperature of not less than 550°C beforedelivery.


2.4.1 At least one tensile test is to be made on materialrepresenting each casting or batch of castings.

2.4.2 Where the casting is of complex design, or wherethe finished mass exceeds 10 tonnes, two test samples are tobe provided. Where large castings are made from two or morecasts which are not mixed in a ladle prior to pouring, two ormore test samples are required corresponding to the number ofcasts involved. These are to be integrally cast at locations aswidely separated as possible.

2.4.3 The results of these tests are to comply with thefollowing requirements:

Yield stress 200 N/mm2 min.Tensile strength 400 N/mm2 min.

Elongation on 5,65 25% min.

Reduction of area 40% min.

2.4.4 A set of three Charpy V-notch impact test specimens is to be provided with each casting in the Specialgrade. These may be taken from a small extension of thethickest part of the casting or from a block cast integrally withthe casting and having dimensions representative of thelargest section thickness of the casting. These are to betested in accordance with Chapter 2 and are to have an average energy of not less than 27J at 0°C.


2.5.1 Castings used in ship construction for the sternframe, rudder and propeller shaft supports are to beexamined by ultrasonic and magnetic particle methods inaccordance with 1.7. The type and extent of non-destructiveexamination of castings for other structural applications areto be specially agreed by the Surveyor.

2.5.2 The extent and methods of non-destructiveexamination to be applied to typical hull steel castings areshown in Figs. 4.2.1 to 4.2.6 in addition to the areasspecified in 1.7.9 and 1.7.10.

2.5.3 Acceptance levels for Visual Inspection are to betaken as follows:(a) No cracks or hot tears are permitted. (b) Castings are to be free of other injurious indications to

the satisfaction of the Surveyor.(c) Additional magnetic particle, dye penetrant or ultrasonic

testing may be required for a more detailed evaluation ofsurface irregularities at the request of the Surveyor.These examinations are in addition to those required by2.6.

So


Chapter 4Section 2



Quality grade Normal Special (see Note 3)

Carbon 0,23% max. 0,23% max.Silicon 0,60% max. 0,60% max.Manganese 0,70–1,60% 0,70–1,60%Sulphur 0,040% max. 0,035% max.Phosphorus 0,040% max. 0,035% max.Aluminium – — 0,015–0,080%(acid soluble) (see Notes 1 and 2)

Residual elements:Copper 0,30% max. 0,30% max.Chromium 0,30% max. 0,30% max.Nickel 0,40% max. 0,40% max.Molybdenum 0,15% max. 0,15% max.Total 0,80% max. 0,80% max.

NOTES1. The total aluminium content may be determined instead of

the acid soluble content, in which case the total aluminiumcontent is to be 0,020–0,10%.

2. Grain refining elements other than aluminium may be usedsubject to special agreement with LR.

3. For the Special grade, the nitrogen content is to be determined.

Steel CastingsRULES FOR THE MANUFACTURE, TESTING AND CERTIFICATION OF MATERIALS, July 2014

Chapter 4Section 2

LLOYD’S REGISTER6

Location of non-destructive examination1. All surfaces: Visual examination2. Location indicated with (ooo): Magnetic particle and Ultrasonic testing

Fig. 4.2.1 Extent of non-destructive evaluation for stern frame castings

B B

A

A

A-A B-B

Location of non-destructive examinationAll surfaces: Visual examination Magnetic particle and ultrasonic testing

Fig. 4.2.2 Extent of non-destructive evaluation for rudder stock castings


Chapter 4Section 2


Location of non-destructive examination1. All surfaces: Visual examination2. Location indicated with (ooo): Magnetic particle and ultrasonic testing3. Location indicated with ( ): Ultrasonic testing

Location of non-destructive examination1. All surfaces: Visual examination2. Location indicated with (ooo): Magnetic particle and Ultrasonic testing3. Location indicated with ( ): Ultrasonic testing

Fig. 4.2.4Extent of non-destructive evaluation for rudder

hanging castings


Fig. 4.2.5 Extent of non-destructive evaluation for rudder (upper part) castings

Fig. 4.2.3Extent of non-destructive evaluation for stern

boss castings

(f) Relevant indication. An indication that is caused by acondition or type of discontinuity that requires evaluation.Only indications which have any dimension greater than1,5 mm are to be considered relevant.

2.6.2 For the purpose of evaluating indications, thesurface is to be divided into reference band length of 150 mmfor level MT1/PT1 and into reference areas of 225 cm2 forlevel MT2/PT2. The band length and/or area is to be taken inthe most unfavourable location, relative to the indicationsbeing evaluated.

2.6.3 The following quality levels recommended formagnetic particle testing (MT) and/or dye penetrant testing(PT) are;(a) Level MT1/PT1 – fabrication weld preparation areas.(b) Level MT2/PT2 – other locations indicated on Figs. 4.2.1

to 4.2.6.The acceptance criteria are shown in Table 4.2.2. Cracks andhot tears are not acceptable.

2.6.4 Acceptance criteria for ultrasonic testing are shownin Table 4.2.3 as UT1 and UT2. Discontinuities within theexamined zones interpreted to be cracks or hot tears, are notacceptable.

2.6.5 Level UT1 is applicable to the following:(a) Fabrication weld preparations for a distance of 50 mm.(b) 50 mm depth from the final machined surface including

boltholes.(c) Fillet radii to a depth of 50 mm and within a distance of

50 mm from the radius end.(d) Castings subject to cyclic bending stresses, e.g., rudder

horn, rudder castings and rudder stocks, the outer onethird of thickness in the zones shown in Figs. 4.2.1 to4.2.6.

2.6.6 Level UT2 is applicable to the following:(a) For locations which are not specified in 2.6.5, nominated

for ultrasonic testing in Figs. 4.2.1 to 4.2.6 or on theinspection plan.

(b) Positions outside locations nominated for level UT1examination where feeders and gates have beenremoved.

(c) Castings subject to cyclic bending stresses, at thecentral one third of thickness in the zones shown in Figs. 4.2.1 to 4.2.6.

2.6 Acceptance levels for surface crack detection

2.6.1 The following definitions apply to indicationsassociated with magnetic particle and dye penetrantinspection:(a) Linear indication. An indication in which the length is at

least three times the width.(b) Non-linear indication. An indication of circular or elliptical

shape with a length less than three times the width.(c) Aligned indication. Three or more indications in a line,

separated by 2 mm or less, edge-to-edge.(d) Open indication. An indication visible after removal of

the magnetic particles, or that can be detected by theuse of contrast dye penetrant.

(e) Non-open indication. An indication that is not visuallydetectable after removal of the magnetic particles, or thatcannot be detected by the use of contrast dye penetrant.


Chapter 4Section 2

LLOYD’S REGISTER8


Fig. 4.2.6Extent of non-destructive evaluation for rudder

(lower part) castings

Maximum number of Maximum numberMaximum dimension of

Quality levelindication

Type of indicationeach type

single indication, mm(see Note 2)

Non-linear 4, see Note 1 5MT1/PT1 4 in 150 mm length Linear 4, see Note 1 3

Aligned 4, see Note 1 3

Non-Linear 10 7MT2/PT2 20 in 22500 mm2 area Linear 6 5

Aligned 6 5

NOTES1. Minimum of 30 mm between relevant indications.2. In weld repairs, the maximum dimension is 2 mm.

Table 4.2.2 Acceptance criteria for surface inspection evaluation


3.2.1 The chemical composition of ladle samples is tocomply with the following limits, except as specified in 3.2.2:

Carbon 0,40% max.Silicon 0,60% max.Manganese 0,50–1,60%Sulphur 0,040% max.Phosphorus 0,040% max.Residual elements:

Copper 0,30% max.Chromium 0,30% max.Nickel 0,40% max.Molybdenum 0,15% max.

Total 0,80% max.

3.2.2 Castings which are intended for parts of a weldedfabrication are to be of weldable quality with a carbon contentgenerally not exceeding 0,23 per cent.

3.2.3 Proposals to use steels with higher carbon content,or alloy steels, for welded construction will be subject tospecial consideration.

3.3 Heat treatment

3.3.1 Castings are to be supplied:(a) fully annealed; or(b) normalised; or(c) normalised and tempered at a temperature of not less

than 550°C; or(d) quenched and tempered at a temperature of not less

than 550°C.

3.3.2 Engine bedplate castings, turbine castings and anyother castings where dimensional stability and freedom frominternal stresses are important, are to be given a stress reliefheat treatment. This is to be at a temperature not lower than550°C, followed by furnace cooling to 300°C or lower.Alternatively, full annealing may be used provided that thecastings are furnace cooled to 300°C or lower.


3.4.1 At least one tensile test is to be made on materialrepresenting each casting or batch of castings.

2.6.7 Ultrasonic acceptance criteria for casting areas notnominated in Figs. 4.2.1 to 4.2.6 will be subject to specialconsideration, based on the anticipated stress levels and thetype, size and position of the discontinuity.

2.6.8 Parts which are welded are to be examined by thesame method as at the initial inspection as well as byadditional methods as required by the Surveyor.

■ Section 3Castings for machineryconstruction

3.1 Scope

3.1.1 This Section gives the material requirements forcarbon-manganese steel castings intended for use in machineryconstruction and which are not within the scope of Sections4 to 7.

3.1.2 Where it is proposed to use steels of higher carboncontent than is indicated in 3.2.1, or alloy steels, particulars ofthe chemical composition, mechanical properties and heattreatment are to be submitted for approval.

3.1.3 The manufacture or repair of cast steel connectingrods is not permitted, except where the manufacturing andquality control procedures have been approved by LR. Forapproval purposes, tests are to be carried out at the place ofmanufacture using the proposed process to demonstrate thatthe castings are sound. Tests are to be carried out to confirmthat the appropriate mechanical properties are attained withinthe casting, including areas where weld repairs have beenperformed. Any changes to manufacturing, repair and quality control procedures are to be submitted to LR forapproval, see also Ch 1,2.2.




Allowable disc shape according Maximum number ofAllowable length of linearQuality level to the Distance-Gain Size indications to be registered,

indications, mm, see Note 2(DGS), mm see Note 1

UT1 >6 0 0

UT2 12–15 5 50>15 0 0

NOTES1. Grouped in an area measuring 300 x 300 mm.2. Measured on the scanning surface.

Table 4.2.3 Ultrasonic acceptance criteria for marine steel castings

3.4.2 Where the casting is of complex design, or wherethe finished mass exceeds 10 tonnes, two test samples are tobe provided. Where large castings are made from two ormore casts which are not mixed in a ladle prior to pouring,two or more test samples are required corresponding to thenumber of casts involved. The test samples are to be integrally cast at locations as widely separated as possible.

3.4.3 Table 4.3.1 gives the minimum requirements foryield stress, elongation and reduction of area correspondingto different strength levels, but it is not intended that theseshould necessarily be regarded as specific grades.Intermediate levels of minimum tensile strength may be specified, in which case minimum values for yield stress, elongation and reduction of area may be obtained by interpolation.

3.4.4 Castings may be supplied to any specified minimum tensile strength selected within the general limitsdetailed in Table 4.3.1.

3.4.5 The results of all tensile tests are to comply with therequirements of Table 4.3.1 appropriate to the specified minimum tensile strength.

3.4.6 For alloy steel castings and carbon-manganesesteel castings containing more than 0,40 per cent carbon, theresults of all mechanical tests are to comply with an approvedspecification.

3.4.7 When a casting, or a batch of castings, has failedto meet the mechanical test requirements, it may be re-heattreated and re-submitted for acceptance tests but this maynot be carried out more than twice, see Ch 1,4.6.


3.5.1 All piston crowns and cylinder covers are to beexamined by ultrasonic testing. In addition, where these castings are intended for engines having a bore size largerthan 400 mm, they are to be examined by magnetic particleor dye penetrant testing in accordance with 1.7.

3.5.2 Engine bedplate castings are to be examined byultrasonic and magnetic particle or dye penetrant testing inaccordance with 1.7.




Tensile Yield stress Elongation Reductionstrength N/mm2 on 5,65 So root of areaN/mm2 minimum % minimum % minimum

400–550 200 25 40440–590 220 22 30480–630 240 20 27520–670 260 18 25560–710 300 15 20600–750 320 13 20

Table 4.3.1 Mechanical properties for acceptancepurposes: carbon and carbon-manganese steel castings formachinery construction

3.5.3 Turbine castings are to be examined by magneticparticle or dye penetrant testing in accordance with 1.7. Inaddition, an ultrasonic or radiographic examination is to bemade in way of fabrication weld preparations.

3.5.4 Other castings are to be examined by non-destruc-tive methods where specified.

■ Section 4Castings for crankshafts

4.1 Scope

4.1.1 This Section gives the requirements for carbon andcarbon-manganese steel castings for semi-built crankshafts.

4.1.2 Where it is proposed to use steels of higher carboncontent than is indicated in 4.3.1, or alloy steels, particulars ofthe chemical composition, mechanical properties and heattreatment are to be submitted for approval. For alloy steels,the specified minimum tensile strength is not to exceed 700 N/mm2.

4.2 Manufacture

4.2.1 The method of producing combined web and pincastings is to be approved. For this purpose, tests to demon-strate the soundness of the casting and the properties atimportant locations may be required.


4.3.1 The chemical composition of ladle samples is tocomply with the following limits:

Carbon 0,40% max. (but see 4.7.4(c))Silicon 0,60% max.Manganese 0,50–1,60%Sulphur 0,040% max.Phosphorus 0,040% max.Residual elements:

Copper 0,30% max.Chromium 0,30% max.Nickel 0,40% max.Molybdenum 0,15% max.

Total 0,80% max.

4.4 Heat treatment

4.4.1 Castings are to be supplied either:(a) fully annealed and cooled in the furnace to a tempera-

ture of 300°C or lower; or(b) normalised and tempered at a temperature of not less

than 550°C, and cooled in the furnace to a temperatureof 300°C or lower.


4.5.1 Proposals for the number of tests and the locationof test material on the casting are to be submitted by themanufacturer.

4.5.2 Not less than one tensile test and three impact testsare to be made on material representing each casting. Theimpact tests are to be carried out at ambient temperature.

4.5.3 Table 4.4.1 gives the minimum requirements foryield stress and elongation corresponding to different strengthlevels, and it is not intended that these should necessarily beregarded as specific grades. The strength levels have beengiven in multiples of 40 N/mm2 to facilitate interpolation forintermediate values of specified minimum tensile strength.

4.5.4 Castings may be supplied to any specified minimum tensile strength selected within the general limitsdetailed in Table 4.4.1.

4.5.5 The results of all tests are to comply with therequirements of Table 4.4.1 appropriate to the specified minimum tensile strength. For the impact tests, one individualvalue may be less than the required average value providedthat it is not less than 70 per cent of this average value. SeeCh 1,4.6 for re-test procedures.


4.6.1 Magnetic particle examination is to be carried outover all surfaces in accordance with Fig. 4.4.1.

4.6.2 Each casting is to be examined by ultrasonic testing, and the extent of examination and defect acceptancecriteria, using the DGS (Distance Gain Size) technique, are tobe as shown in Fig. 4.4.2. Alternative ultrasonic proceduresmay be submitted for approval.



Chapter 4Section 4

4.7 Rectification of defective castings

4.7.1 The requirements of 1.9 apply, except whereamended by this Section.

4.7.2 Where castings have shallow surface defects,consideration is first to be given to removing such defects bygrinding and blending or by machining the surface wherethere is excess metal on the Rule dimension.

4.7.3 Subject to prior agreement and submission of thedetailed welding procedure for approval by LR, welding maybe carried out prior to the final austenitising heat treatment.

4.7.4 Approval for welding will not be given in the followingcircumstances:(a) For the rectification of repetitive defects caused by

improper foundry technique or practice.(b) For the building up by welding of surfaces or large

shallow depressions.(c) Where the carbon content of the steel exceeds 0,30 per

cent.(d) Where the carbon equivalent of the steel, given by

C + + + exceeds 0,65 per cent.

4.7.5 Provided that the Surveyors are satisfied that weldingis justified, they may also authorise welding to the surfaces ofcrankwebs, following the final austenitising heat treatment,within the following limits:(a) In general, the volume of the largest groove which is to

be welded is not to exceed 3,2t cm3, where t is the webaxial thickness, in cm. The total volume of all grooveswhich are to be welded is not to exceed 9,6t cm3 percrankweb.

(b) The welds do not extend within the cross-hatched zonesmarked on Fig. 4.4.3 for semi-built crank throws.

(c) Larger welds on balance weights may be permitted atthe discretion of the Surveyor, provided that such repairsare wholly contained within the balance weight and donot affect the strength of the crankweb.

4.7.6 Subsequent to the final austenitising heat treat-ment, welding may be authorised in the surface of the borefor the journal (or pin) within the following limits:(a) In general, the welds are to be not less than 125 mm

apart.(b) The welds are not to be located within circumferential

bands of from the edges of the bores, nor at any

position within the inner 120° arc of the bores, as cross-hatched on Fig. 4.4.3.

(c) The volume of the largest weld is to be not more than1,1t cm3, where t is the web axial thickness at the bore,in cm, and not more than three welds are to be made inany one bore surface.

4.7.7 After all defective material has been removed froma region, and this has been proven in the presence of theSurveyor by magnetic particle inspection or other suitablemethod, the excavation is to be suitably shaped to allow goodaccess for welding.

t5

Mn6

Cr + Mo + V5

Ni + Cu15

Table 4.4.1 Mechanical properties for acceptancepurposes: carbon-manganese steelcastings for crankshafts

Charpy Elongation V-notch

Tensile Yield on Reduction impact strength stress 5,65 So of area testsN/mm2 N/mm2 % % average

minimum minimum minimum energyJ minimum(see Note)

400–550 200 28 45 32440–590 220 26 45 28480–630 240 24 40 25520–670 260 22 40 20550–700 275 20 35 18

NOTEImpact tests are to be made at ambient temperature.

4.7.12 Welds are to be dressed smooth by grinding. Thesurfaces of the welds and adjacent parent steel are to beproven by magnetic particle and, where appropriate, ultra-sonic inspection, see 1.9.15 and 1.9.14.

4.7.8 At the discretion of the Surveyor, the size of agroove may be increased beyond the limiting sizes given in4.7.5 or 4.7.6, if the removal of further metal will facilitatewelding.

4.7.9 Welding is to be carried out by approved weldersusing approved procedures. The welds are to be made by anelectric arc process using low hydrogen type consumableswhich will produce a deposited metal that is not inferior inproperties to the parent metal.

4.7.10 All castings are to be given a preliminary refiningheat treatment prior to the commencement of welding. Beforewelding, the material is to be preheated in accordance withthe qualified procedure. Where possible, preheating is to becarried out in a furnace. The preheat temperature is to bemaintained until welding is completed, and preferably until thecasting is placed in the furnace for post-weld heat treatment.

4.7.11 Where welding is carried out after the final austeni-tising heat treatments, a post-weld stress relieving heattreatment is to be applied at a temperature of not less than600ºC, see also 1.5.2.



Chapter 4Section 4

b

c c

D

A BSection A–A Section B–B

ea

L

A B

d θθ

Zone 1 : Any actual defects with one dimension of 0,5 mm or more are not acceptable

Zone 2 : Any actual defects with one dimension of 2 mm or more are not acceptable



θ = 90 a = 0,1d b = 0,1d c = 0,05D e = L/4

d = pin diameter D = journal diameter 5291/06

Fig. 4.4.1 Magnetic particle inspection acceptance levels

■ Section 5Castings for propellers

5.1 Scope

5.1.1 This Section gives the requirements for steel castings for one-piece propellers and separately cast bladesand hubs for fixed pitch and controllable pitch propellers(CPP). These include contra-rotating propellers, azipods andazimuth thrusters. The requirements for copper alloypropellers, blades and hubs are given in Ch 9,1.

5.1.2 These castings are to be manufactured and testedin accordance with the appropriate requirements of Chapters 1and 2 and Ch 4,1 as well as the requirements of this Section.

5.1.3 Full details of the manufacturer’s specification areto be submitted for approval. These should include the chemicalcomposition, heat treatment, mechanical properties, micro-structure and repair procedures.

5.1.4 Special requirements are given for castings whichare intended for ice service in Table 4.5.2.




30 mm

b b

D

A BSection A–A Section B–B

ca

L

A B

d

Zone 1 : Max. allowable flaw size equivalent to a flat bottomed diameter 3 mm hole

Zone 2 : Max. allowable flaw size equivalent to a flat bottomed diameter 6 mm hole

a = 0,1d b = 0,05D c = L/6

d = Pin diameter D = Journal diameter 5291/07

100 mm

Fig. 4.4.2 Ultrasonic examination acceptance levels

120°

0,2t

0,15d

d

t

0,2t 0,2t0,6t

0,15d

120°

d

Fig. 4.4.3Areas of semi-built crank throws to which weld

repairs are not permitted

5.4.3 At least one tensile test and for the martensiticstainless steel grades one set of three Charpy V-notch impacttests are to be made on material representing each casting.The results are to comply with the requirements of Table 4.5.2or the approved specification.

5.4.4 As an alternative to 5.4.3, where a number of smallpropeller castings of about the same size, and less than 1 min diameter, are made from one cast and heat treated togetherin the same furnace, a batch testing procedure may beadopted using separately cast test samples of suitable dimensions. At least one set of mechanical tests is to beprovided for each multiple of five castings in the batch.

5.4.5 Separately cast test bars may be used subject toprior approval of the Surveyor. Test bars must be cast fromthe same heat, or heats, and must also be heat treated withcastings they represent.


5.5.1 On completion of machining and grinding, thewhole surface of each casting is to be examined in accordance with Ch 9,1.8.

5.5.2 When appropriate, magnetic particle inspectionmay be used in lieu of liquid penetrant testing.

5.5.3 Castings are to be free from cracks and hot tears.


5.2.1 The chemical composition of ladle samples is tocomply with the approved specification, see 5.1.3.

5.2.2 Typical cast steel propeller alloys are given in Table 4.5.1.

5.3 Heat treatment

5.3.1 Martensitic stainless steel castings are to beaustenitised, quenched and tempered in accordance with theapproved specification, see 5.1.3.

5.3.2 Austenitic stainless steel castings are to be solutiontreated in accordance with the approved specification, see5.1.3.


5.4.1 The test material is to be cast integral with the bossof propeller castings, or with the flange of separately castpropeller blades. Alternatively, the test material may beattached on blades in an area between 0,5 and 0,6R, whereR is the radius of the propeller.

5.4.2 The test material is not to be removed from the casting until final heat treatment has been carried out. Removalis to be by non-thermal procedures.

Yield stress or, Tensile strength Elongation onCharpy V-notch

Alloy type 0,2% proof stress minimum 5,65 SoReduction of impact tests

minimum, N/mm2 N/mm2 % minimumarea % minimum J minimum (see

Notes 1 and 2)

Martensitic (12Cr 1Ni) 440 590 15 30 20



Austenitic (19Cr 11Ni) 180 (see Note 3) 440 30 40 —

NOTES1. When a general service notation Ice Class 1AS, 1A, 1B or 1C is required, the tests are to be made at –10°C.2. For general service or where the notation Ice Class 1D is required, the tests are to be made at 0°C.3. Rp1,0 value is 205 N/mm2.



Table 4.5.1 Typical chemical composition for steel propeller castings

Alloy type C Max. (%) Mn Max. (%) Cr (%) Mo Max. (%) (see Note) Ni (%)

Martensitic (12Cr 1Ni) 0,15 2,0 11,5–17,0 0,5 Max. 2,0

Martensitic (13Cr 4Ni) 0,06 2,0 11,5–17,0 1,0 3,5–5,0

Martensitic (16Cr 5Ni) 0,06 2,0 15,0–17,5 1,5 3,5–6,0

Austenitic (19Cr 11Ni) 0,12 1,6 16,0–21,0 4,0 8,0–13,0

NOTEMinimum values are to be in accordance with the agreed specification or recognised National or International Standards.

Table 4.5.2 Typical mechanical properties for steel propeller castings

Chapter 4Section 5


5.8.1 In addition to the requirements in Ch 4,1.11, themanufacturer is to provide the Surveyor with a written state-ment giving the following particulars for each casting:(a) Description of casting with drawing number.(b) Diameter, number of blades, pitch, direction of turning.(c) Skew angle, if in excess of 25°.(d) Final mass.(e) Vessel identification, where known.

■ Section 6Castings for boilers, pressurevessels and piping systems

6.1 Scope

6.1.1 This Section gives the requirements for carbon-manganese and alloy steel castings for boilers, pressurevessels and piping systems for use at temperatures not lowerthan 0°C.

6.1.2 Where it is proposed to use alloy steels other thanas given in this Section, details of the specification are to besubmitted for approval. In such cases, the specified minimumtensile strength is not to exceed 600 N/mm2.

6.1.3 Castings which comply with these requirements areacceptable for liquefied gas piping systems where the designtemperature is not lower than 0°C. Where the design temper-ature is lower than 0°C, and for other applications whereguaranteed impact properties at low temperatures arerequired, the castings are to comply with the requirements ofSection 7 or 8.


6.2.1 The chemical composition of ladle samples is tocomply with the limits specified in Table 4.6.1.

6.3 Heat treatment

6.3.1 Castings are to be supplied:(a) fully annealed; or(b) normalised; or(c) normalised and tempered; or(d) quenched and tempered.


6.4.1 A tensile test is to be made on material representingeach casting, unless a batch testing procedure has beenagreed, see 1.6.

6.4.2 The tensile test is to be carried out at ambienttemperature, and unless agreed otherwise with the Surveyor,the results are to comply with the requirements of Table 4.6.2.


5.6.1 The rectification of defective castings is to beundertaken in accordance with 1.9 and the following paragraphs.

5.6.2 Removal of defective material is to be by mechanicalmeans, e.g., by grinding, chipping or milling. The resultantgrooves are to be blended into the surrounding surface so asto avoid any sharp contours.

5.6.3 Grinding in severity zone A may be carried out toan extent that maintains the blade thickness. Repair by weldingis generally not permitted in zone A and will only be allowedafter special consideration.

5.6.4 Defects in severity zone B that are not deeper thant/40 mm (t is the minimum local thickness according to theRules) or 2 mm, whichever is the greater, are to be removedby grinding. Those defects that are deeper may be repairedby welding subject to prior approval of the Surveyor.

5.6.5 Repair welding is generally permitted in severityzone C.

5.6.6 Welds having an area of less than 5 cm2 are to beavoided. The maximum surface area of repairs is to be inaccordance with Table 9.1.4 in Chapter 9.

5.6.7 Welding is to be in accordance with the approvedspecification, see 5.1.3.

5.6.8 After weld repair, the propeller or blade is to be heattreated in such fashion as will minimise the residual stresses.For martensitic stainless steels, this will involve full heat treatment as specified in the approved specification.

5.6.9 LR reserves the right to restrict the amount of repairwork accepted from a manufacturer when it appears thatrepetitive defects are the result of improper foundry techniques or practices.

5.6.10 All welds are to be inspected by the appropriateNDE method, see 1.7.

5.7 Identification

5.7.1 Castings are to be clearly marked by the manufac-turer in accordance with the requirements of Chapter 1. Thefollowing details are to be shown on all castings which havebeen accepted:(a) Identification mark which will enable the full history of the

item to be traced.(b) Type of steel, this should include or allow identification

of the chromium and nickel contents.(c) LR or Lloyd’s Register and the abbreviated name of

Lloyd’s Register’s local office.(d) Personal stamp of Surveyor responsible for the final

inspection.(e) LR certificate number.(f) Skew angle, if in excess of 25°.(g) Ice class symbol, where applicable.(h) Date of final inspection.




6.4.3 Where it is proposed to use a carbon-manganesesteel with a specified minimum tensile strength intermediate tothose given in this Section, corresponding minimum valuesfor the yield stress, elongation and reduction of area may beobtained by interpolation.

6.4.4 Carbon-manganese steels with a specified minimum tensile strength of greater than 490 N/mm2, but notexceeding 520 N/mm2, may be accepted provided thatdetails of the proposed specification are submitted forapproval.


6.5.1 The non-destructive examination of castings is tobe carried out in accordance with the appropriate require-ments of 1.7.7 to 1.7.11 and additionally as agreed betweenthe manufacturer, purchaser and Surveyor.


6.6.1 Nominal values for the minimum lower yield or 0,2 per cent proof stress at temperatures of 100°C and higherare given in Table 4.6.3. These values are intended for designpurposes only, and verification is not required except for materials complying with National or proprietary specificationswhere the elevated temperature properties used for designpurposes are higher than those given in Table 4.6.3.

6.6.2 In such cases, at least one tensile test at theproposed design or other agreed temperature is to be madeon each casting or each batch of castings. The test specimenis to be taken from material adjacent to that used for tests atambient temperature, and the test procedure is to be inaccordance with the requirements of Chapter 2. The results ofall tests are to comply with the requirements of the National orproprietary specification.




Yield stress Tensile Elongation ReductionType of steel minimum strength on 5,65 So of area

N/mm2 N/mm2 % minimum % minimum

Carbon-manganese 275 485-655 22 25

1/2Mo 260 460-590 18 30

1Cr1/2Mo 280 480-630 17 20

21/4 Cr1 Mo 325 540-630 17 20

1/2Cr1/2Mo1/4V 295 510-660 17 20

Table 4.6.2 Mechanical properties for acceptance purposes: steel castings for boilers, pressure vessels andpiping systems


Type of steelC Si Mn S P Residual elements

max. max. max. max.

Cr 0,30 max.Mo 0,15 max.

Carbon-manganese 0,25 0,60 0,50-1,20 0,040 0,040 Cu 0,30 max.Ni 0,40 max.

Total 0,80 max.

Residual elementsCr Mo V Cr Cu Ni

1/2 Mo 0,20 0,60 0,50–1,00 0,040 0,040 — 0,45-0,65 — 0,30 0,30 0,40max. max. max.

1 Cr 1/2 Mo 0,20 0,60 0,50-0,80 0,040 0,040 1,00-1,50 0,45-0,65 — — 0,30 0,40max. max.

2 1/4 Cr1 Mo 0,18 0,60 0,40-0,70 0,040 0,040 2,00-2,75 0,90-1,20 — — 0,30 0,40max. max.

1/2 Cr 1/2 Mo 1/4 V 0,10–0,15 0,45 0,40-0,70 0,030 0,030 0,30-0,50 0,40-0,60 0,22-0,30 — 0,30 0,30max. max.

Table 4.6.1 Chemical composition of steel castings for boilers, pressure vessels and piping systems

Chapter 4Section 6

■ Section 7Ferritic steel castings for lowtemperature service

7.1 Scope

7.1.1 This Section gives the requirements for castings incarbon-manganese and nickel alloy steels, intended for usein liquefied gas piping systems where the design temperatureis lower than 0°C, and for other applications where guaran-teed impact properties at low temperatures are required.

7.1.2 Where it is proposed to use alternative steels,particulars of the specified chemical composition, mechanicalproperties and heat treatment are to be submitted forapproval.


7.2.1 The chemical composition of ladle samples is tocomply with the limits specified in Table 4.7.1. Carbon-manganese steels are to be made by fine grain practice.

7.3 Heat treatment

7.3.1 Castings are to be supplied:(a) normalised; or(b) normalised and tempered; or(c) quenched and tempered.


7.4.1 One tensile test and one set of three Charpy V-notch impact test specimens are to be prepared from material representing each casting or batch of castings.

7.4.2 The tensile test is to be carried out at ambienttemperature, and the results are to comply with the appropriate requirements given in Table 4.7.2.

7.4.3 The average value for impact test specimens is tocomply with the appropriate requirements given in Table 4.7.2.One individual value may be less than the required averagevalue provided that it is not less than 70 per cent of this average value. See Ch 2,1.4 for re-test procedure.


7.5.1 The non-destructive examination of castings is tobe carried out in accordance with the appropriate require-ments of 1.7.7 to 1.7.11 and additionally agreed between themanufacturer, purchaser and Surveyor.





Type of steelTemperature °C

100 150 200 250 300 350 400 450 500 550 600

Carbon-manganese 225 214 201 186 163 156 152 — — — —

1/2Mo 242 236 226 207 186 175 169 158 145 136 126

1Cr1/2Mo 240 — 212 — 196 — 184 — 160 — 117

21/4Cr1 Mo 323 312 305 296 290 280 273 258 240 211 180

1/2Cr1/2Mo1/4V 264 — 244 — 230 — 214 — 194 — 144

Table 4.6.3 Mechanical properties for design purposes (see 6.6.1)

Table 4.6.4 Mechanical properties for designpurposes (see 6.6.3): estimatedaverage stresses to rupture in 100,000 hours (N/mm2)

Type of steelTemperature

°C 1/2Mo 1Cr1/2Mo 21/4Cr1Mo 1/2Cr1/2Mo1/4V

430 308 — — —440 276 — — —450 245 — 222 277460 212 — 199 237470 174 236 177 206

480 133 186 156 181490 103 148 139 159500 84 120 124 140510 71 100 111 124520 60 84 99 109

530 — 70 — 96540 — 58 — 85550 — — — 75560 — — — 66



8.3 Heat treatment

8.3.1 Austenitic stainless steel castings are to be solutiontreated, at a temperature of not less than 1000°C and cooledrapidly in water.

8.3.2 Duplex stainless steels castings are to be solutiontreated at a temperature of not less that 1100°C and cooledrapidly in water.


8.4.1 One tensile test specimen is to be prepared frommaterial representing each casting or batch of castings. In addition, where the castings are intended for liquefied gasapplications, where the design temperature is lower than–55°C, one set of three Charpy V-notch impact test specimensis to be prepared.

8.4.2 The tensile test is to be carried out at ambienttemperature, and the results are to comply with the require-ments given in Table 4.8.2.

■ Section 8Stainless steel castings

8.1 Scope

8.1.1 This Section gives the requirements for castings inaustenitic and duplex stainless steels for machinery, marinestructures, piping systems in ships for liquefied gases, and inbulk chemical tankers.

8.1.2 Austenitic stainless steels castings are suitable forapplications where the lowest design temperature is not lowerthan –165°C.

8.1.3 Duplex stainless steels castings are suitable forapplications where the lowest design temperature is above0°C. Any requirement to use duplex stainless steels castingsbelow 0°C will be subject to special consideration.

8.1.4 Where it is proposed to use alternative steels,particulars of the specified chemical composition, mechanicalproperties and heat treatment are to be submitted forapproval.



Charpy V-notch impact testYield stress Tensile Elongation Reduction

Type of steel Grade N/mm2 strength on 5,65 So or area Test Average

minimum N/mm2 % minimum % minimum temperature energy°C J minimum

Carbon-manganese 400 200 400-550 25 40430 215 430-580 23 35 –60 27460 230 460-610 22 30 (see Note)

21/4Ni 490 275 490-640 20 35 –70 34

31/2Ni 490 275 490-640 20 35 –95 34

Table 4.7.2 Mechanical properties for acceptance purposes: ferritic steel castings for low temperature service

NOTEThe test temperature for carbon-manganese steels may be 5°C below the design temperature if the latter is above –55°C, with a maximum testtemperature of –20°C.

Table 4.7.1 Chemical composition of ferritic steel castings for low temperature service


Type of steel C Si Mn S P Ni Residualmax. max. max. max. elements

max.

Carbon-manganese 0,25 0,60 0,70-1,60 0,030 0,030 0,80 max.

21/4Ni 0,25 0,60 0,50-0,80 0,025 0,030 2,00-3,00

31/2Ni 0,15 0,60 0,50-0,80 0,020 0,025 3,00-4,00

Cr 0,25Cu 0,30Mo 0,15V 0,03

Total 0,60


Steel Castings

8.4.3 The average value for impact test specimens is tocomply with the appropriate requirements given in Table 4.8.2.One individual value may be less than the required averagevalue, provided that it is not less than 70 per cent of this average value. See Ch 2,1.4 for re-test procedures.



8.5 Corrosion tests

8.5.1 Where corrosive conditions are anticipated inservice, for grades 304, 316 and 317, intergranular corrosiontests are required in accordance with Ch 2,8.1. Such testsmay also be required for grades 304L, 316L and 347.

Chapter 4Section 8

Charpy V-notch impact testsTensile strength 1,0% proof stress Elongation Reduction

Type of steel N/mm2 N/mm2 on 5,65 So of area Test Averageminimum minimum % minimum % minimum temperature energy

°C J minimum

Austenitic

304L 430 21526 40 –196 41

304 480 220

316L 430 215

316 480 220 26 40 –196 41

317 480 240

347 480 215 22 35 –196 41

Duplex

UNS J 92205 600 420 20 35 0 41(see Note)

NOTEThe grade UNS J 92205 is the cast equivalent of UNS S 31803.

Table 4.8.2 Mechanical properties for acceptance purposes: stainless steel castings

Table 4.8.1 Chemical composition of stainless steel castings

Chemical composition %Type ofsteel

C Si Mn S P Cr Mo Ni Others

Austenitic

304L 0,03 — 8,0–12,0 —

304 0,08 — 8,0–12,0 —

316L 0,03 2,0–3,0 9,0–13,0 —

316 0,08 0,20-1,5 0,50-2,0 0,040 17,0-21,0 2,0–3,0 9,0–13,0 —

317 0,08 3,0–4,0 9,0–12,0 —

Nb347 0,06 — 9,0–12,0 ≥ 8 x C(see Note 1) ≤ 0,90

Duplex

UNS J 0,03 1,00 1,50 0,020 0,035 21,0–23,0 2,5–3,5 4,5–6,5 N92205 0,15–0,20(see Note 3) Cu 1,00

NOTES1. When guaranteed impact values at low temperature are not required, the maximum carbon content may be 0,08% and the maximum

niobium may be 1,00%.2. Where a single value is shown (and not a range of values), the value is to be taken as maximum.3. The grade UNS J 92205 is the cast equivalent of UNS S 31803.

9.2.2 The chemical composition of the ladle samples isto comply with the limits given in Table 4.9.1.

9.2.3 The carbon equivalent:

Ceq = C + + + (%)

must not exceed 0,45 per cent.

9.3 Heat treatment

9.3.1 Castings are to be supplied either:(a) normalised; or(b) water or oil quenched and tempered at a temperature of

not less than 550°C.


9.4.1 At least one tensile test is to be made on eachbatch of castings, using separately cast test bars which are tobe from the same cast and heat treatment lot as the castings they represent.

9.4.2 The results of the tensile tests are to comply withthe following:

Yield stress 220 N/mm2 min.Tensile strength 430–600 N/mm2

Elongation on 25% min.Reduction of area 40% min.

9.4.3 Impact tests are not required on all casts, but maybe required on a random basis at the discretion of theSurveyor.

9.4.4 When required, the impact test specimens are tobe tested in accordance with Ch 1,4.5 and Ch 2,3.2. Ingeneral, tests are to be made at a temperature of –20°C andthe minimum average energy obtained is to be 27J.


9.5.1 Ultrasonic or radiographic testing is to be carriedout, in accordance with 1.7.10 or 1.7.11 respectively, on atleast one casting from each cast or from every 400 castings,whichever is the lesser.

So

Mn6

Cr + Mo + V5

Ni + Cu15

8.5.2 Where corrosive conditions are anticipated inservice, for duplex stainless grades pitting corrosion tests arerequired in accordance with ASTM G48 Method C. For duplexstainless steel grade UNS J 92205 the test temperature is tobe 20°C. Following the test, no pitting corrosion is to beobserved at 20x magnification. The use of a weight lossmethod may be accepted subject to special consideration.


8.6.1 The non-destructive examination of castings is tobe carried out in accordance with the appropriate require-ments of 1.7.7 to 1.7.11 and additionally agreed between themanufacturer, purchaser and Surveyor.

■ Section 9Steel castings for containercorner fittings

9.1 General

9.1.1 This Section gives the requirements for cast steelcorner fittings used in the fabrication of freight and tankcontainers. The fittings are also to comply with the require-ments of the latest edition of International Standard ISO 1161.

9.1.2 The castings are to be made in foundries approvedby LR. These foundries are also to be specially approved forthe manufacture of container corner castings. In order tocomply with these requirements, the manufacturer is requiredto verify that the casting soundness, mechanical properties,weldability and dimensional tolerances required by thisSection and the manufacturing specification are met.

9.1.3 Castings may be released on the basis of an LRsurvey or, alternatively, the manufacturer may be approved bymeans of a Quality Assurance Scheme as detailed in Ch 1,2.


9.2.1 Chemical analysis is to be carried out on each cast.




Table 4.9.1 Chemical composition of steel castings for container corner fittings


AlC Mn Si P S Cr Ni Cu Mo acid soluble Cr + Ni + Cu + Mo

max. max. max. max. max. max. max. max. min. max.(See Notes)

0,900,20 to 0,50 0,035 0,035 0,25 0,30 0,20 0,08 0,015 0,70

1,50

NOTES1. The total aluminium content may be determined instead of the acid soluble content. In such cases, the total aluminium content is to be

not less than 0,02%.2. Aluminium may be replaced partly or totally by other grain refining elements as stated in the approved specification.



Chapter 4Section 9

9.6 Repair of defects

9.6.1 Minor defects may be removed by grinding providedthat the allowable minus tolerance is not exceeded.

9.6.2 Defects which exceed the allowable minus tolerance may be removed by grinding or chipping followedby welding, provided the weld depth does not exceed 40 per cent of the wall thickness and that the followingrequirements are met:(a) welding is not to be carried out in the as-cast condition;

the grain structure has to be refined by heat treatment,(b) the casting is to be preheated to 80–100°C,(c) welding is to be performed only by qualified welders in

accordance with a qualified welding procedure,(d) all welded castings are to be post-weld heat treated at a

temperature not less than 550°C,(e) the welded areas are to be ground or machined flush

with the adjacent surface and inspected by magneticparticle or dye penetrant examination as appropriate.

9.7 Identification

9.7.1 Each casting is to be clearly marked by the manufacturer with at least the following:(a) manufacturer’s name or trade mark,(b) cast number or identification number which will enable

the full history of the casting to be traced.

9.7.2 Where the casting has been inspected and foundacceptable it is to be marked with the Surveyor’s personalstamp.

9.7.3 The markings may be stamped or cast on the innersurface of the casting.


9.8.1 For each consignment an LR certificate, see Ch 1,3.1, is to be issued for castings made under LR surveyor alternatively a manufacturer’s certificate is to be issuedcontaining at least the following:(a) Purchaser’s name and order number.(b) Grade of steel.(c) Drawing and/or specification number.(d) Cast number and chemical composition.(e) Details of the heat treatment.(f) Number and weight of the castings.(g) Results of inspections and mechanical tests.See Ch 1,3.1, for manufacturers approved under a QualityAssurance Scheme.

Steel Forgings

Section


2 Forgings for ship and other structuralapplications

3 Forgings for shafting and machinery

4 Forgings for crankshafts

5 Forgings for gearing

6 Forgings for turbines

7 Forgings for boilers, pressure vessels andpiping systems

8 Ferritic steel forgings for low temperatureservice

9 Stainless steel forgings


1.1 Scope

1.1.1 This Section gives the general requirements forsteel forgings intended for use in the construction of ships,other marine structures, machinery, boilers, pressure vesselsand piping systems. These requirements are also applicableto rolled slabs and billets used as a substitute for forgings andto rolled bars used for the manufacture (by machining operations only) of shafts, bolts, studs and other componentsof similar shape.

1.1.2 When required by the relevant Rules dealing withdesign and construction, forgings are to be manufactured andtested in accordance with Chapters 1 and 2, together withthe general requirements given in this Section and the appropriate specific requirements given in Sections 2 to 9.

1.1.3 As an alternative to 1.1.2, steel forgings whichcomply with National or proprietary specifications, may beaccepted provided that these specifications give reasonableequivalence to the requirements of this Chapter, or alternativelyare approved for a specific application. Generally, survey andcertification are to be carried out in accordance with therequirements of Chapter 1.

1.1.4 Normalised forgings with mass up to 1000 kg eachmay be batch tested. A batch is to consist of forgings of similar shape and dimensions, made from the same steel-making heat, heat treated together and with a total mass notexceeding 6 tonnes.

1.1.5 Quenched and tempered forgings with mass up to500 kg each may be batch tested. A batch is to consist offorgings of similar shape and dimensions, made from thesame steel-making heat, heat treated together in the samefurnace and with a total mass not exceeding 3 tonnes.

1.1.6 A batch testing procedure may also be used forhot rolled bars, see 3.4.3.

1.1.7 Where small forgings are produced in large quantities, or where forgings of the same type are producedin regular quantities, alternative survey procedures in accor-dance with Ch 1,2.4 may be adopted.

1.2 Manufacture

1.2.1 Forgings are to be made at works which have beenapproved by Lloyd’s Register (hereinafter referred to as LR).The steel used, is to be manufactured in accordance with therequirements of Ch 3,1.4.

1.2.2 When forgings are made directly from ingots, orfrom blooms or billets forged from ingots, the ingots are to becast in chill moulds with the larger cross-section uppermostand with efficient feeder heads.

1.2.3 Adequate top and bottom discards are to be madeto ensure freedom from piping and harmful segregations inthe finished forgings.

1.2.4 The forgings are to be gradually and uniformly hotworked and are to be formed as closely as possible to thefinished shape and size. The plastic deformation is to be suchas to ensure soundness, uniformity of structure and satisfactorymechanical properties after heat treatment.

1.2.5 For certain components, such as crankshafts, wheregrain flow is required in the most favourable direction, havingregard to the mode of stressing in service, the proposedmethod of manufacture may require special approval by LR. Insuch cases, tests may be required to demonstrate that a satisfactory structure and grain flow are obtained.

1.2.6 The reduction ratio (reduction of area expressed asa ratio) is to be calculated with reference to the average cross-sectional area of the ingot or continuously cast material,where appropriate. Where an ingot is initially upset, this reference area may be taken as the average cross-sectionalarea after this operation.

1.2.7 For components forged directly from ingots or fromforged blooms or billets, and in which the fibre deformation ismainly longitudinal, the reduction ratio is not to be less than 3:1.

1.2.8 For forgings made from rolled billets, or where fibredeformation has taken place in more than one direction, thereduction ratio is not to be less than 4:1.

1.2.9 Where rolled bars are used as a substitute for forgings and the requirements of 1.2.2 are not complied with,the reduction ratio is to be not less than 6:1.

1.2.10 Where the length of any section of a shaft forging isless than its diameter (e.g., a collar), the reduction ratio is to benot less than half that given in 1.2.7, 1.2.8 or 1.2.9 respectively.


Chapter 5Section 1


Steel Forgings

1.2.11 Disc type forgings, such as gear wheels, are to bemade by upsetting, and the thickness of any part of the discis to be not more than one-half of the length of the billet fromwhich it was formed, provided that this billet has received aninitial forging reduction of not less than 1,5:1. Where the pieceused has been cut directly from an ingot, or where the billethas received an initial reduction of less than 1,5:1, the thickness of any part of the disc is to be not more than one-third of the length of the original piece.

1.2.12 Rings and other types of hollow forgings are to bemade from pieces cut from ingots or billets and which havebeen suitably punched, bored or trepanned prior to expandingor hollow forging. Alternatively, pieces from hollow cast ingotsmay be used. The wall thickness of the forging is to be notmore than one-half of the thickness of the prepared hollowpiece from which it was formed. Where this is not practicable,the forging procedure is to be such as to ensure thatadequate work is given to the piece prior to punching, etc.This may be either longitudinal or upset working of not lessthan 2:1.

1.2.13 The shaping of forgings or rolled slabs and billetsby flame cutting, scarfing or arc-air gouging is to be under-taken in accordance with recognised good practice and,unless otherwise approved, is to be carried out before the finalheat treatment. Preheating is to be employed where necessitated by the composition and/or thickness of the steel.For certain components, subsequent machining of all flamecut surfaces may be required, see 4.2.4.

1.2.14 Where two or more forgings are joined by weldingto form a composite component, details of the proposedwelding procedure are to be submitted for approval. Weldingapproval procedure tests may be required.

1.3 Quality

1.3.1 All forgings are to be free from surface or internaldefects which would be prejudicial to their proper applicationin service.


1.4.1 All forgings are to be made from killed steels, andthe chemical composition of ladle samples is to comply withthe requirements detailed in subsequent Sections in thisChapter. Where general overall limits are specified, the chemical composition selected is to be appropriate for thetype of steel, dimensions and required mechanical propertiesof the forgings being manufactured.

1.4.2 Except where otherwise specified, suitable grainrefining elements such as aluminium, niobium or vanadiummay be used at the discretion of the manufacturer. Thecontent of such elements is to be reported in the ladle analysis.

1.4.3 For alloy steel forgings, the chemical compositionof ladle samples is to generally comply with the following overall limits and the requirements of the approved specifica-tions:

Carbon 0,45% max.Silicon 0,45% max.Manganese 0,30% min.Sulphur 0,035% max.Phosphorus 0,035% max.Copper 0,30% max.

And at least one of the following elements is to comply withthe minimum content:

Chromium 0,40% min.Molybdenum 0,15% min.Nickel 0,40% min.

The contents of all alloying elements and significant impuritiesdetailed in the specification are to be reported.

1.5 Heat treatment

1.5.1 At an appropriate stage of manufacture, aftercompletion of all hot working operations, forgings are to besuitably heat treated to refine the grain structure and to obtainthe required mechanical properties. Acceptable heat treatment procedures are to be such as to avoid the formationof hair-line cracks and are detailed in Sections 2 to 9.

1.5.2 Heat treatment is to be carried out in a properlyconstructed furnace which is efficiently maintained and hasadequate means of temperature control. The furnace dimen-sions are to be such as to allow all the steel forgings to beuniformly heated to the necessary temperature. In the caseof very large forgings, alternative methods of heat treatmentwill be specially considered. Sufficient thermocouples are tobe connected to the steel forging(s) in the furnace to showthat the temperature is adequately uniform and the tempera-tures are to be recorded throughout the heat treatment.Copies of these records are to be presented to the Surveyortogether with a sketch showing the positions at which thetemperature measurements were carried out. The records areto identify the furnace that was used and give details of thesteel-making heat, the heat treatment temperature, time attemperature and the date. The Surveyor is to examine thecharts and confirm the details on the certificate. Alternativeprocedures are to be approved by LR’s Materials and NDEDepartment.

1.5.3 Where forgings are to be quenched and temperedand cannot be hot worked close to size and shape, they areto be suitably rough machined or flame cut prior to beingsubjected to this treatment.

1.5.4 If for any reason a forging is subsequently heatedfor further hot working, the forging is to be reheat treated.

1.5.5 If any straightening operation is performed after thefinal heat treatment, consideration should be given to asubsequent stress relieving heat treatment in order to avoidthe possibility of harmful residual stresses.


Chapter 5Section 1

LLOYD’S REGISTER2

Steel Forgings

1.5.6 Where it is intended to surface harden forgings, fulldetails of the proposed procedure and specification are to besubmitted for approval. For the purposes of this approval, themanufacturer will be required to demonstrate by tests that theproposed procedure gives a uniform surface layer of therequired hardness and depth and that it does not impair thesoundness and properties of the steel.

1.5.7 Where induction hardening or nitriding is to becarried out after machining, forgings are to be heat treated atan appropriate stage to a condition suitable for this subsequent surface hardening.

1.5.8 Where carburising is to be carried out after machining,forgings are to be heat treated at an appropriate stage (generally either by full annealing or by normalising andtempering) to a condition suitable for subsequent machiningand carburising.

1.5.9 The forge is to maintain records of heat treatmentidentifying the furnace used, furnace charge, thermocouplelocation, date, temperature and time at temperature. Therecords are to be presented to the Surveyor on request.

1.6 Test material

1.6.1 Test material, sufficient for the required tests andfor possible re-test purposes, is to be provided with a cross-sectional area of not less than that part of the forging which itrepresents. This test material is to be integral with each forging, except in the case of small forgings which are batchtested, see 1.6.4.

1.6.2 Where a forging is subsequently divided into anumber of components, all of which are heat treated togetherin the same furnace, for test purposes this may be regardedas one forging and the number of tests required is to berelated to the total length and mass of the original multipleforging, see 2.4.2.

1.6.3 Except for components which are to be carburised,test material is not to be cut from a forging until the heat treatment detailed in Sections 2 to 9 has been completed.The testing procedure for components which are to becarburised is to be in accordance with the details given inSection 5.

1.6.4 Where a number of small forgings of about thesame size are made from one cast and heat treated togetherin the same furnace, batch testing procedures (see 1.1.4) maybe adopted using one of the forgings for test purposes, oralternatively using separately forged test samples. These testsamples are to have a forging reduction similar to that usedfor the forgings which they represent. They are to be properlyidentified and heat treated together with the forgings.


1.7.1 Specimens for mechanical tests are to be preparedas required by Sections 2 to 9.

1.7.2 Test specimens are normally to be cut with theiraxes mainly parallel (longitudinal test) or mainly tangential(tangential test) to the principal axial direction of each product.

1.7.3 Unless otherwise agreed, the longitudinal axis ofthe test specimens is to be positioned as follows:(a) for thickness or diameter ≤ 50 mm, the axis is to be at

the mid-thickness or the centre of the cross-section;(b) for thickness or diameter > 50 mm, the axis is to be at

one quarter thickness (mid-radius) or 80 mm, whicheveris less, below any heat treated surface;

Test pieces shall be taken in such a way that no part of thegauge length is machined from material closer than 12,5 mmto any heat treated surface. For impact testing, this require-ment is to apply to the complete test piece.

1.7.4 Tensile test specimens are to be machined to thedimensions detailed in Chapter 2. Where this is precluded bythe dimensions of the forging, the test specimen is to be ofthe largest practicable cross-sectional area.

1.7.5 Impact test specimens are to be prepared in accordance with the requirements of Chapter 2.

1.7.6 The procedures used for the tensile and impacttests are to be in accordance with the requirements ofChapter 2.

1.7.7 Hardness tests, preferably of the Brinell type, are tobe carried out when specified in subsequent Sections in thisChapter.


1.8.1 Before acceptance, all forgings are to be presentedto the Surveyor for visual examination. Where applicable, thisis to include the examination of internal surfaces and bores.

1.8.2 Forgings are to be examined in the condition forfinal delivery. Surfaces are to be clean and free from dirt,grease, paint, etc. Black forgings are to be suitably descaledby either shotblasting or flame descaling methods.

1.8.3 All forgings are to be free of cracks, crack-like indications, laps, seams, folds, or other injurious indications.At the request of the Surveyor, additional magnetic particle,dye penetrant and ultrasonic testing may be required for amore detailed evaluation of surface irregularities.

1.8.4 When specified in subsequent Sections in thisChapter, or by an approved procedure for welding compositecomponents, see 1.2.14, appropriate non-destructive examination is also to be carried out before acceptance. Alltests are to be carried out in accordance with the requirements of Ch 1,5.


Chapter 5Section 1


Steel Forgings

1.8.5 Magnetic particle and dye penetrant testing is to becarried out when the forgings are in the finished machinedcondition, see also Ch 1,2.3.5. For magnetic particle testing,attention is to be paid to the contact between the forging andthe clamping devices of stationary magnetisation benches inorder to avoid local overheating or burning damage on itssurface. Prods are not permitted on finished machined items.Unless otherwise agreed, these tests are to be carried out inthe presence of the Surveyor.

1.8.6 The following definitions apply to indications asso-ciated with magnetic particle and dye penetrant inspection:(a) Linear indication. An indication in which the length is at

least three times the width.(b) Nonlinear indication. An indication of circular or

elliptical shape with a length less than three times thewidth.

(c) Aligned indication. Three or more indications in a line,separated by 2 mm or less edge-to-edge.

(d) Open indication. An indication visible after removal ofthe magnetic particles or that can be detected by theuse of contrast dye penetrant.

(e) Non-open indication. An indication that is not visuallydetectable after removal of the magnetic particles or thatcannot be detected by the use of contrast dye penetrant.

(f) Relevant indication. An indication that is caused by acondition or type of discontinuity that requires evalua-tion. Only indications which have any dimension greaterthan 1,5 mm are to be considered relevant.

1.8.7 Acceptance standards for defects found by visualor non destructive examinations are to be in accordance withany specific requirements of the approved plan, and withequivalence to any additional requirements of this Chapter. Inall cases they are to be to the satisfaction of the Surveyor.

1.8.8 Where required, ultrasonic examination is to becarried out after the forgings have been machined to a condition suitable for this type of examination and after thefinal heat treatment. Both radial and axial scanning are to becarried out where appropriate for the shape and the dimensions of the forgings being examined. Scanning is totake into account near surface examination. Unless otherwiseagreed, examinations are to be carried out by the manufacturer, although Surveyors may request to be presentin order to verify that the examination is being carried out inaccordance with the agreed procedure.

1.8.9 If the forging is supplied in the black condition formachining at a separate works, the manufacturer is to ensurethat a suitable ultrasonic examination is carried out to verifythe internal quality of the forging.

1.8.10 In the circumstance detailed in either 1.8.8 or 1.8.9,the manufacturer is to provide the Surveyor with a signed report confirming that ultrasonic examination has been carriedout and that such inspection has not revealed any significantinternal defects.

1.8.11 Unless otherwise agreed, the accuracy and verification of dimensions are the responsibility of the manufacturer.

1.8.12 In the event of any forging proving defective duringsubsequent machining or testing, it is to be rejected notwith-standing any previous certification.

1.8.13 When required by the conditions of approval forsurface hardened forgings (see 1.5.6) additional test samplesare to be processed at the same time as the forgings whichthey represent. These test samples are subsequently to besectioned in order to determine the hardness, shape anddepth of the locally hardened zone and which are to complywith the requirements of the approved specification.


1.9.1 Small surface imperfections may be removed bygrinding or by chipping and grinding. Complete elimination ofthese imperfections is to be proved by magnetic particle ordye penetrant examination (as appropriate to the material). Atthe discretion of the Surveyor, the resulting shallow grooves ordepressions can be accepted, provided that they are blendedby grinding.

1.9.2 Repairs by welding are not generally permitted, butspecial consideration will be given to such repairs where theyare of a minor nature and in areas of low working stresses. Insuch cases, full details of the proposed repair and subsequentinspection procedures are to be submitted for review by theSurveyors prior to the commencement of the proposed rectification. A report and/or sketch detailing the extent andlocation of all repairs, together with details of the post-weldheat treatment and non-destructive examination are to beprovided for record purposes and are to be attached to thecertificate.

1.9.3 Repair welding is not permitted for crankshafts orsimilar rotating components.

1.9.4 Where fabrication welding is involved, see 1.2.14,any repair of defects is to be carried out in accordance withthe approved welding procedure.

1.9.5 The forging manufacturer is to maintain records ofrepairs and subsequent inspections traceable to each forging.The records are to be presented to the Surveyor on request.

1.9.6 Non-open indications evaluated as segregation areacceptable.

1.10 Identification

1.10.1 The manufacturer is to adopt a system of identifi-cation, which will enable all finished forgings to be traced tothe original cast, forging process and heat treatment batch,and the Surveyor is to be given full facilities for so tracing the castings when required.


Chapter 5Section 1

LLOYD’S REGISTER4

Steel Forgings

1.10.2 Forgings are to be clearly marked by the manufac-turer in accordance with the requirements of Chapter 1. Thefollowing details are to be shown on all forgings which havebeen accepted:(a) Identification number, cast number or other marking

which will enable the full history of the forging to betraced.

(b) LR or Lloyd’s Register and the abbreviated name of LR’slocal office.

(c) Personal stamp of Surveyor responsible for inspection.(d) Test pressure, where applicable.(e) Date of final inspection.

1.10.3 Modified arrangements for the identification of smallforgings manufactured in large numbers, as with closed-dieforgings may be agreed with the Surveyor.



1.11.2 The manufacturer is to provide the Surveyor with awritten statement giving the following particulars for each forging or batch of forgings which has been accepted:(a) Purchaser’s name and order number.(b) Description of forgings and steel quality.(c) Identification number.(d) Steel-making process, cast number and chemical

analysis of ladle samples.(e) General details of heat treatment.(f) Results of mechanical tests.(g) Test pressure, where applicable.

1.11.3 As a minimum, the chemical composition of ladlesamples is to include the content of all the elements detailedin the specific requirements.

1.11.4 Where applicable, the manufacturer is also toprovide a signed report regarding ultrasonic examination asrequired by 1.8.8, a report of magnetic particle inspection anda statement and/or sketch detailing all repairs by welding asrequired by 1.9.2.

1.11.5 When steel is not produced at the works at which itis forged, a certificate is to be supplied by the steelmaker stating the process of manufacture, cast number and thechemical composition of ladle samples. The works at whichthe steel was produced is to have been approved by LR, see1.4.3.

■ Section 2Forgings for ship and otherstructural applications

2.1 Scope

2.1.1 This Section gives the specific requirements forcarbon-manganese steel forgings intended for ship and otherstructural applications such as rudder stocks, pintles, etc.

2.1.2 Where it is proposed to use an alloy steel, particu-lars of the chemical composition, mechanical properties andheat treatment are to be submitted for approval, see 1.4.3.


2.2.1 For forgings to which structural items are to beattached by welding or which are intended for parts of a fabricated component, or are to be weld cladded or may besubject to weld repair in service, the chemical composition ofladle samples is to comply with the following:

Carbon 0,23% max.Silicon 0,45% max.Manganese 0,30–1,50% but not less than 3 times theactual carbon content for components which are notgiven a post-weld heat treatmentSulphur 0,035% max.Phosphorus 0,035% max.Residual elements:

Copper 0,30% max.Chromium 0,30% max.Molybdenum 0,15% max.Nickel 0,40% max.Total 0,85% max.

For samples from forgings, the carbon content is not toexceed 0,26 per cent.

2.2.2 It is recommended that forgings for rudder stocks,pintles and rudder coupling bolts comply with 2.2.1 in order toobtain satisfactory weldability for any future repairs by weldingin service.

2.2.3 For forgings not intended for welding the carboncontent may be 0,65 per cent max., see 3.2.1.

2.3 Heat treatment

2.3.1 Carbon-manganese steel forgings are to be:(a) fully annealed; or(b) normalised; or(c) normalised and tempered at a temperature of not less

than 550°C.(d) quenched and tempered.

2.3.2 Alloy steel forgings are to be quenched and thentempered at a temperature of not less than 550°C.Alternatively, they may be supplied in the normalised andtempered condition, in which case the specified mechanicalproperties are to be agreed by LR.


2.4.1 At least one tensile specimen is to be taken fromeach forging or batch of forgings.

2.4.2 Where a forging exceeds both 4 tonnes in massand 3 m in length, tensile test specimens are to be taken fromeach end. These limits refer to the ‘as forged’ mass andlength but exclude the test material.




Steel Forgings

2.4.3 Unless otherwise agreed between the manufac-turer and the Surveyor, the test specimens are to be cut in a longitudinal direction.

2.4.4 The results of all tensile tests are to comply with therequirements given in Table 5.2.1 appropriate to the specifiedminimum tensile strength. Forgings may be supplied to anyspecified minimum tensile strength within the general limitsgiven in Table 5.2.1, and intermediate values may be obtainedby interpolation. See 2.4.6 for rudder stocks, pintles, andrudder coupling keys and bolts.

2.4.5 For large forgings, where tensile tests are takenfrom each end, the variation in tensile strength is not toexceed 70 N/mm2.

2.4.6 For rudder stocks, pintles, and rudder couplingkeys and bolts, the minimum specified yield strength is not tobe less than 200 N/mm2, see Table 13.2.4 in Pt 3, Ch 13.

2.4.7 Impact tests are required for rudder stocks to befitted to vessels which have an ice class notation. The testsare to be carried out at minus 10°C and the average energyvalue is to be not less than 27J.


2.5.1 Surface inspections are to be carried out by visualexamination and magnetic particle testing (or dye penetranttesting where appropriate).

2.5.2 Surface inspections are to be carried out in thezones I and II as indicated in Fig. 5.2.1.

2.5.3 For the purpose of evaluating indications, thesurface is to be divided into reference areas of 225 cm2. Thearea is to be taken in the most unfavourable location relative tothe indication being evaluated.

2.5.4 The allowable number and size of indications in thereference area is given in Table 5.2.2.

2.5.5 Volumetric inspection is to be carried out byultrasonic testing using the contact method.

2.5.6 Ultrasonic testing is to be carried out on rudderstocks having a finished diameter of 200 mm or greater.

2.5.7 Ultrasonic testing is to be carried out in the zones Ito III as indicated in Fig. 5.2.2. Areas may be upgraded to ahigher zone at the discretion of the Surveyor.


Chapter 5Section 2

LLOYD’S REGISTER6

Inspection zoneMaximum number of

Type of indicationMaximum number Maximum dimension,

indications each type mm

Linear 0, see Note —I 3 Non-linear 3 3,0

Aligned 0, see Note —

Linear 3, see Note 3,0II 10 Non-linear 7 5,0

Aligned 3, see Note 3,0

NOTELinear or aligned indications are not permitted on bolts, which receive a direct fluctuating load, e.g., main bearing bolts, connecting rod bolts,crosshead bearing bolts and cylinder cover bolts.

Table 5.2.2 Steel forgings surface inspection

Table 5.2.1 Mechanical properties for ship and other structural applications

Yield stress Tensile Elongation on 5,65 So min.% Reduction of area min. %Steel type N/mm2 strength

minimum N/mm2 Long. Tang. Long. Tang.

180 360-480 28 20 50 35200 400-520 26 19 50 35220 440-560 24 18 50 35235 470-590 23 17 45 35240 480-600 22 16 45 30

C and C-Mn 260 520-640 21 15 45 30280 560-680 20 14 40 27300 600-750 18 13 40 27320 640-790 17 12 40 27340 680-830 16 12 35 24360 720-870 15 11 35 24380 760-910 14 10 35 24350 550-570 20 14 50 35

Alloy 400 600-750 18 13 50 35450 650-800 17 12 50 35

2.5.8 Ultrasonic acceptance criteria are shown in Table 5.3.4, alternatively see Ch 1,5.

Steel ForgingsRULES FOR THE MANUFACTURE, TESTING AND CERTIFICATION OF MATERIALS, July 2014

Chapter 5Section 2


Up(c) Type C

II

Up

3 x shaft dia.

L

L/3

L: length of the tapered portion

(a) Type A

I

IIII

Up

3 x shaft dia.

(b) Type B

I

II

II

NOTE Welded areas are to be treated as Zone I

Fig. 5.2.1 Inspection zones for magnetic particle/dye penetrant testing on rudder stocks


Chapter 5Section 2

LLOYD’S REGISTER8

(c) Type CUp

III

(a) Type A

Up

3 x shaft dia.

L

L/3

L: length of the tapered portionII

IIIIII

(b) Type B

Up

3 x shaft dia.

II

III

III

NOTE

Special consideration is given to the welded areasaxial

axial

axial

axial

180° radial

axial

axial

axial

axial

360° radial 180° radial

Zone II Zone III

Scanning direction for Type A and Type B

Lower part

Upper part

Scanning directionfor Type C

NOTE

Axial scan from end face also required for Type A and Type B

Fig. 5.2.2 Inspection zones for ultrasonic testing on rudder stocks

3.4.2 Where a forging exceeds both 4 tonnes in massand 3 m in length, a tensile test is to be taken from each end.These limits refer to the ‘as forged’ mass and length butexclude the test material.

3.4.3 A batch testing procedure may be used for hotrolled bars not exceeding 250 mm diameter, which areintended for the manufacture (by machining operations only)of straight shafting, bolts, studs and other machinery components of similar shape. A batch is to consist of either:(a) material from the same piece provided that where this is

cut into individual lengths, these are all heat treatedtogether in the same furnace; or

(b) bars of the same diameter and cast, heat treatedtogether in the same furnace and with a total mass not exceeding 2,5 tonnes.

3.4.4 The test specimens are to be taken in the longitudinal direction but, at the discretion of the manufac-turer and if agreed by the Surveyor, alternative directions or positions as shown in Figs. 5.3.1 to 5.3.3 may be used.

3.4.5 For carbon-manganese steels, Table 5.3.1 givesthe minimum requirements for yield stress, elongation andreduction of area, corresponding to different strength levels,but it is not intended that these should necessarily beregarded as specific grades. Intermediate values for otherspecified minimum tensile strengths should be calculated byinterpolation.

■ Section 3Forgings for shafting andmachinery

3.1 Scope

3.1.1 Detailed in this Section are the requirements forcarbon-manganese steel forgings for shafting and other itemsof machinery which are not within the scope of Sections 4 to 8.

3.1.2 Where it is proposed to use alloy steel forgings,particulars of the chemical composition, mechanical properties and heat treatment are to be submitted forapproval. For main propulsion shafting in alloy steels, thespecified minimum tensile strength is not to exceed 800 N/mm2 (800–950 N/mm2 acceptance range) and forother forgings is not to exceed 1100 N/mm2 (1100–1300 N/mm2 acceptance range).


3.2.1 The chemical composition of ladle samples forcarbon and carbon-manganese steels is to comply with thefollowing overall limits:

Carbon 0,65% max.Silicon 0,45% max.Manganese 0,30–1,50%Sulphur 0,035% max.Phosphorus 0,035% max.Residual elements:

Copper 0,30% max.Chromium 0,30% max.Molybdenum 0,15% max.Nickel 0,40% max.Total 0,85% max.

3.2.2 For alloy steels, see 1.4.3.

3.2.3 For forgings to which structural items are to beattached by welding, or which are intended for parts of a fabricated component, are to be of weldable quality, see2.2.1.

3.3 Heat treatment

3.3.1 Forgings are to be:(a) fully annealed; or(b) normalised; or(c) normalised and tempered; or(d) quenched and tempered.The tempering temperature is to be not less than 550°C.


3.4.1 At least one tensile test is to be made on each forging, or each batch of forgings. Impact tests are notrequired except on screwshafts for ice service, see 3.4.12.


Chapter 5Section 3


Longitudinal

Tangential

Fig. 5.3.1Directions and positions of test specimens

Tangential

Longitudinal(through bolt hole) Longitudinal


3.4.6 Forgings may be supplied to any specified minimum tensile strength selected within the general limitsdetailed in Table 5.3.1, except that for main propulsion shafting forgings the specified minimum tensile strength is tobe not less than 400 N/mm2 (400–520 N/mm2 acceptancerange) and not greater than 600 N/mm2 (600–750 N/mm2

acceptance range) see shaded area of Table 5.3.1.

3.4.7 The results of all tensile tests are to comply with therequirements given in Table 5.3.1 appropriate to the specifiedminimum tensile strength.

3.4.8 The minimum requirements for yield stress, elon-gation and reduction of area, corresponding to differentstrength levels in alloy steel forgings are given in Table 5.3.2.

Tensile strength N/mm2 Yield stress N/mm2 Elongation on 5,65 So min.% Reduction of area min. %

Long. Tang. Long. Tang.

360–480 180 28 20 50 35400–520 200 26 19 50 35440–560 220 24 18 50 35470–590 235 23 17 45 35480–600 240 22 16 45 30520–640 260 21 15 45 30560–680 280 20 14 40 27600–750 300 18 13 40 27640–790 320 17 12 40 27680–830 340 16 12 35 24

700–850 2 350 15 11 35 24720–870 2 360 15 11 35 24760–910 2 380 14 10 35 24

NOTES1. For main propulsion shafting forgings, the specified minimum tensile strength is to be between 400 and 600 N/mm2 (shaded area of

Table) see 3.4.6.2. Where the specified minimum tensile strength exceeds 700 N/mm2, forgings are to be supplied only in the quenched and tempered

condition.

Table 5.3.1 Mechanical properties for acceptance purposes: carbon and carbon-manganese steel forgings formachinery and shafting

Tangential

Tangential Tangential

Longitudinal


Chapter 5Section 3


Elongation on 5,65 So min.% Reduction of area min. %Tensile strength N/mm2 Yield stress N/mm2

Long. Tang. Long. Tang.

600–750 420 18 14 50 35650–-800 450 17 13 50 35700–850 480 16 12 45 30750–900 530 15 11 45 30800–950 580 14 10 40 27850–1000 630 13 9 40 27900–1100 690 13 9 40 27950–1150 750 12 8 35 241000–1200 810 12 8 35 241050–1250 870 11 7 35 241100–1300 930 11 7 35 24

NOTEFor main propulsion shafting forgings, the minimum specified tensile strength is not to exceed 800 N/mm2, see 3.4.9 (shaded area of Table).

Table 5.3.2 Mechanical properties for acceptance purposes: alloy steel forgings for machinery and shafting


3.5.2 The areas to be tested by magnetic particle or dyepenetrate testing are shown in Fig. 5.3.4 and Fig. 5.3.5. Areasof other components not shown in these figures are to beagreed with the Surveyor. For tie rods, only threaded portionsand the adjacent material over a length equal to that of thethread need be tested.

3.5.3 Surface inspection acceptance criteria are to be inaccordance with 2.5. Other acceptance criteria may beapplied, providing they meet these minimum criteria, and areto the satisfaction of the Surveyor.

3.5.4 Ultrasonic testing is to be carried out in accordancewith 2.5 on the following items:(a) Shafts having a finished diameter of 200 mm or larger

when intended for main propulsion or other essentialservices.

(b) All piston crowns and cylinder covers.(c) Piston rods and connecting rods for engines having a

bore diameter greater than 400 mm.The areas to be tested are shown in Fig. 5.3.6 and Fig. 5.3.7.Areas of other components not shown in these drawings areto be agreed with the Surveyor.

3.5.5 Ultrasonic acceptance criteria are shown in Table 5.3.3. Other acceptance criteria may be applied,providing they meet these minimum criteria, and are to thesatisfaction of the Surveyor.


Chapter 5Section 3


3.4.9 Forgings in alloy steels may be supplied to anyspecified minimum tensile strength selected within the generallimits detailed in Table 5.3.2, and minimum yield stress, elongation and reduction of area, obtained by interpolation,except that for main propulsion shafting forgings the specified minimum tensile strength is not to exceed 800 N/mm2 (800–950 N/mm2 acceptance range) see shadedarea of Table 5.3.2.

3.4.10 The results of all tensile tests are to comply with therequirements given in Table 5.3.2 appropriate to the specifiedminimum tensile strength.

3.4.11 Where more than one tensile test is taken from aforging, the variation in tensile strength is not to exceed thefollowing:

Specified minimum Difference intensile strength tensile strengthN/mm2 N/mm2

<600 70≥600 < 900 100≥900 120

3.4.12 For screwshafts intended for ships with the notation Ice Class 1AS or 1A and where the connectionbetween the propeller and the screwshaft is by means of akey, a set of three Charpy V-notch impact tests (longitudinaltest) is to be made on material from the propeller end of eachshaft. The tests are to be carried out at –10°C and the average energy value is to be not less than 20 J.


3.5.1 Magnetic particle or dye penetrant testing (whereappropriate) is to be carried out on forgings for main propul-sion shafting (including propeller shafts, intermediate shafts,and thrust shafts with minimum diameter not less than 100 mm), on all connecting rod forgings and on the followingcomponents when they are intended for engines having abore diameter larger than 400 mm:

Cylinder coversPiston crownsPiston rodsTie rodsGear wheels for camshaft drivesBolts and studs for:

Cylinder coversCrossheadsMain bearingsConnecting rod bearingsPropeller blade fastening boltsCrankpin boltsTie rod boltsAdditionally, bolts for engine bore diameters ofless than 400 mm but having a minimum diame-ter 50 mm or greater (which are subjected todynamic stress), are also to be subjected tosurface examinations.


Chapter 5Section 3


(b) Intermediate shaft

II

(c) Thrust shaft

II

NOTE

For propeller shaft, intermediate shafts and thrust shafts, all areas with stress raisers such as radial holes,slots and key ways are to be treated as Zone I.

(a) Propeller shaft

I

I

II

II

L

L/3150 mm

L: length of the tapered portionFore

Fore

250 mm

II

IIII

Fig. 5.3.4 Zones for magnetic particle/dye penetrant testing on machinery components


Chapter 5Section 3


II

II

I

L

(b) Piston rod

II

(c) Cross head

II

II

II

(a) Connecting rod

NOTE

Thread, holes and their circumstances are to betreated as Zone I

(d) Bolt

I

II IIL

L: Length of thread

L: Length of thread

Fig. 5.3.5 Zones for magnetic particle/dye penetrant testing on machinery components


Chapter 5Section 3


NOTES

1. For hollow shafts, 360° radial scanning applies to Zone III2. Circumferences of the bolt holes in the flanges are to be treated as Zone II3. Axial scan from end face also required

(a) Propeller shaft

II

250 mm

Fore

III

II

II

250 mm

Fore

IIIIII

(b) Intermediate shaft

III

(c) Thrust shaft

III

Zone II Zone III

axial

axial axial

axial


Fig. 5.3.6 Zones for ultrasonic testing on shafts


Chapter 5Section 3


III

(c) Cross head

Zone II Zone III

axial

axial axial

axial


Scanning direction

(a) Connecting rod (b) Piston rod

III

III

II

L

L: length of thread

III

III

IIIII250 mm

250 mm

r-end

r-end

NOTE

Axial scan from end face also required

Fig. 5.3.7 Zones for ultrasonic testing on machinery components

4.2.3 For combined crankweb and pin forgings, theproposed method of forging is to be submitted for approval.It is recommended that these forgings be made by a foldingmethod. Other methods which can be shown to producesound forgings with satisfactory mechanical properties will beconsidered, but where the gapping method is used for crankshaving a pin diameter exceeding 510 mm this will only beaccepted provided that an upsetting operation is included inthe manufacturing sequence. In general, the amount of workduring the upsetting operation is to be such that the reductionin the original length of the ingot (after discard) or bloom is notless than 50 per cent.

4.2.4 Where crankwebs are flame cut from forged orrolled slabs, the procedure used is to be in accordance with1.2.13, and additionally, unless specially agreed, a depth ofat least 7,5 mm is to be removed by machining from all flame-cut surfaces.


4.3.1 The chemical composition of ladle samples is tocomply with 3.2.1 for carbon and carbon-manganese steelsand 1.4.3 for alloy steels.

4.3.2 For alloy steel forgings which are to be nitrided, thephosphorus or sulphur contents are not to exceed 0,02 percent.

4.4 Heat treatment

4.4.1 For forgings in all types of steels, heat treatment isto be either:(a) normalising and tempering, or(b) quenching and tempering.The temperature used for tempering is to be not less than550°C.

■ Section 4Forgings for crankshafts

4.1 Scope

4.1.1 The specific requirements for solid forgedcrankshafts and forgings for use in the construction of fullybuilt and semi-built crankshafts are detailed in this Section.

4.1.2 Where it is proposed to use alloy steel forgings, particulars of the chemical composition (see 1.4.3), heat treatment and mechanical properties are to be submitted forapproval. The specified minimum tensile strength is not toexceed 1000 N/mm2 (1000–1200 N/mm2 acceptance range).

4.2 Manufacture

4.2.1 For closed die and continuous grain flowcrankshafts forgings, where an allowance is given for designpurposes, full details of the proposed method of manufactureare to be submitted for approval. In such cases, tests will berequired to demonstrate that a satisfactory structure and grainflow are obtained. The number and positions of test specimens are to be agreed with LR.

4.2.2 For the manufacture of welded crankshafts,approval is required for the welding procedure.




Allowable disc shapeaccording to Distance Allowable length of

Type of forging Zone Gain Size (DGS), indication, see Note 1, mm

mm see Note 2

Propeller shaft Outer d ≤ 2 ≤10Intermediate shaft II Inner d ≤ 4 ≤15

Thrust shaft Outer d ≤ 3 ≤10Rudder stock III Inner d ≤ 6 ≤15

Connecting rod II d ≤ 2 ≤10Piston rod

III d ≤ 4 ≤10

NOTES1. Outer part means the part beyond one third of the shaft radius from the centre. The inner part means the remaining core area.2. For accumulations of two or more isolated indications which are subjected to registration, the minimum distance between two

neighbouring indications is to be at least the length of the larger indication.

Table 5.3.3 Acceptance criteria for ultrasonic testing

4.5.3 The number and position of test specimens fromcombined crankweb and pin forgings are to be in accordancewith the requirements of the approved method of manufac-ture.

4.5.4 For other crankshaft forgings, tests are to be takenas detailed in Section 3, except that for crankwebs the testspecimens are to be cut in a tangential direction.

4.5.5 As an alternative to 4.5.2, small solid forgedcrankshafts may be batch tested in accordance with 1.6.4,provided that, in addition, hardness tests are carried out oneach forging.

4.5.6 Tables 5.4.1 to 5.4.3 give the minimum require-ments for yield stress and elongation corresponding todifferent strength levels, but it is not intended that theseshould necessarily be regarded as specific grades. Thestrength levels have been given in multiples of 40 N/mm2, or50 N/mm2 in the case of alloy steels, to facilitate interpolationfor intermediate values of specified minimum tensile strength.

4.4.2 Where it is proposed to surface harden crankshaftforgings by nitriding or induction hardening, full details of theproposed procedure are to be submitted as required by 1.5.6.


4.5.1 At least one tensile test specimen is to be takenfrom each forging.

4.5.2 For solid forged crankshafts, tests are to be takenin the longitudinal direction from the coupling end of each forging (test position A in Fig. 5.4.1). Where the mass, as heattreated but excluding test material, exceeds 3 tonnes, asecond set of tests is to be taken from the end opposite thecoupling, in addition (test position B in Fig. 5.4.1). Where thecrankthrows are formed by machining or flame cutting, thesecond set of tests is to be taken in a tangential direction frommaterial removed from the crankthrow at the end opposite thecoupling (test position C in Fig. 5.4.1).For continuous grainflow (CGF) crankshaft forgings, where insufficient materialexists for a second longitudinal test, the second set of testsmay be taken in a tangential direction from the crankthrow(test position C in Fig. 5.4.2).


Chapter 5Section 4


ElongationYield stress on 5,65 So

HardnessTensile strength N/mm2 % minimum Brinell

N/mm2minimum

Long. Tang.

400–520 200 26 19 110–150440–560 220 24 18 125–160480–600 240 22 16 135–175520–640 260 21 15 150–185560–680 280 20 14 160–200600–750 300 18 13 175–215640–790 320 17 12 185–230680–830 340 16 12 200–240720–870 350 15 11 210–250760–910 380 14 18 225–265

Intermediate values may be obtained by interpolation.

Table 5.4.1 Mechanical properties for acceptancepurposes: carbon-manganese steelforgings for crankshafts

3108/01

Test position A(longitudinal)

Test position B(longitudinal)

Test position C(tangential)Coupling end

Fig. 5.4.1 Solid forged crankshaft


Test position C(tangential)

Test position B(longitudinal)

Fig. 5.4.2 CGF Crankshaft

4.5.10 For small crankshaft forgings which have beenbatch tested, the hardness values are to be not less thanthose given in Tables 5.4.1 to 5.4.3, as appropriate. The variation in hardness in each batch is to comply with thefollowing:

Specified minimum tensile Difference in hardnessstrength (N/mm2) (Brinell number)<600 not more than 25≥600 <900 not more than 35≥900 not more than 42


4.6.1 Magnetic particle or dye penetrant testing asdetailed in 1.8.5 and 2.5 is to be carried out on all forgingsfor crankshafts. Where applicable, this is to include allsurfaces which have been flame-cut, but not subsequentlymachined during manufacture. Particular attention is to begiven to the testing of the pins, journals and associated filletradii of solid forged crankshafts and to the pins and fillet radiiof combined web and pin forgings. The extent of testing isshown in Fig. 5.4.3.

4.6.2 The manufacturer is to carry out an ultrasonicexamination of all forgings as detailed in 1.8.8 and 2.5, exceptthat for closed-die forgings this examination may, subject toapproval, be confined to the initial production and to subsequent occasional checks. The extent of ultrasonic testing is shown in Fig. 5.4.4.

4.6.3 Surface inspection acceptance criteria are to be inaccordance with 2.5 and with Table 5.4.4. Other acceptancecriteria may be applied, providing they meet these minimumcriteria, and is to the satisfaction of the Surveyor.

4.6.4 Ultrasonic acceptance criteria are shown in Table 5.4.5.Other acceptance criteria may be applied, providing theymeet these minimum criteria, and is to the satisfaction of theSurveyor.4.5.7 Forgings may be supplied to any specified minimum

tensile strength selected within the general limits detailed inTables 5.4.1 to 5.4.3.

4.5.8 The results of all tensile tests are to comply with therequirements of Table 5.4.1, 5.4.2 or 5.4.3 appropriate to thespecified minimum tensile strength.



<600 70≥600 <900 100≥900 120


Chapter 5Section 4


Yield stressElongation

Tensile strengthN/mm2 on 5,65 So Hardness

N/mm2minimum

% minimum Brinell

Long. Tang.

600–750 330 18 14 175–215650–800 355 17 13 190–235700–850 380 16 12 205–245750–900 405 15 11 215–260800–950 430 14 10 235–275


Table 5.4.2 Mechanical properties for acceptancepurposes: alloy steel forgings forcrankshafts – Normalised andtempered

Tensile strength

Yield stress Elongation

N/mm2N/mm2 on 5,65 So Hardness

minimum % minimum Brinell

Long. Tang.

600–750 420 18 14 175–215650–800 450 17 13 190–235700–850 480 16 12 205–245750–900 530 15 11 215–260800–950 590 14 10 235–275850–1000 640 13 9 245–290900–1100 690 13 9 260–320950–1150 750 12 8 275–3401000–1200 810 12 8 290–365


Table 5.4.3 Mechanical properties for acceptancepurposes: alloy steel forgings forcrankshafts – Quenched andtempered


Chapter 5Section 4


db

db

db

2db

a

a

a a

a

a

A

A

B

B

II

I II

II

II

II

II

II

θ θ

θ θ

(a) Soild crankshaft

NOTES

1. Where the crankpin or journal has oil holes, the circumferential surfaces of the oil are to be treated as Zone I, (see the figure on the right)2. In the above figures: θ = 60° a = 1,5r b = 0,05d (: circumferential surfaces of shrinkage fit) where r : fillet radius d : journal diameter3. Identification of the Zones: : Zone I : Zone II

(b) Semi built-up crankshaft

aa a

b

b

b

b

A

A

B

B

III IIII

II

II

II

II

θθ

Section B-B

Section B-BSection A-A

Section A-A

db: Oil hole bore diameter

Fig. 5.4.3 Zones for magnetic particle/dye penetrant testing on crankshafts


Chapter 5Section 4


Scanning direction

(a) Solid crankshaft


a a

a a

A

A

B

B

I I I

IIIIII III

IIIIII III

NOTES

1. In the above figures: a = 0,1d or 25 mm, whichever is greater b = 0,05d or 25 mm, whichever is greater (: circumstances of shrinkage fit) where d : pin or journal diameter2. The mid third area of crank pins and/or journals within a raduis of 0,25d between the webs may generally be coordinated to Zone II3. Identification of the Zones: : Zone I : Zone II : Zone III

(b) Semi built-up crankshaft

a a

A

A

B

B

b b


II I

IIII

III

IIIIII

IIIIII

IIIIII

b

II

II II II

II

II

II

II II II II

Fig. 5.4.4 Zones for ultrasonic testing on crankshafts

Steel Forgings

■ Section 5Forgings for gearing

5.1 Scope

5.1.1 Provision is made in this Section for carbon-manganese and alloy steel forgings intended for use in theconstruction of gearing for main propulsion and for driving electric generators.

5.1.2 Gear wheel and rim forgings with a specified minimum tensile strength not exceeding 760 N/mm2

(760–910 N/mm2 acceptance range) may be made in carbon-manganese steel. Gear wheel or rim forgings where thespecified minimum tensile strength is in excess of 760 N/mm2,and all pinion or pinion sleeve forgings, are to be made in asuitable alloy steel. Specifications for alloy steel componentsand for quill shafts, giving chemical composition, heat treatment and mechanical properties, are to be submitted forapproval.

5.1.3 Forgings for flexible couplings, quill shafts and gearwheel shafts are to comply with the requirements of Section 3.

5.1.4 Manufacturers’ test certificates for forgings may beaccepted where the transmitted power does not exceed 220 kW (300 shp) for main propulsion and 100 kW (150 shp)for auxiliary drives.

5.2 Manufacture

5.2.1 All forgings are to be made with sufficient materialto allow an adequate machining allowance on all surfaces forthe removal of unsound or decarburised material.

5.2.2 The hardenability of the forged material is to bechecked at random intervals using an end quench testcomplying with a National or International Standard.

5.2.3 The grain size is to be checked on a random basisin accordance with the testing and reporting procedures ofASTM E 112, or an equivalent National Standard, and is to bewithin the range 5 to 8.

5.2.4 The microstructure of the hardened case is to bemainly martensite, with a maximum content of 15 per cent ofretained austenite.


5.3.1 The chemical composition of ladle samples is tocomply with 3.2.1. for carbon and carbon-manganese steelsand 1.4.3 for alloy steels.




Inspection zoneMaximum number of

Type of indicationMaximum number Maximum dimension of

indication each type single indication, mm

I Linear 0 —Critical fillet area 0 Non-linear 0 —

Aligned 0 —

II Linear 0 —Important fillet area 3 Non-linear 3 3,0

Aligned 0 —

III Linear 0 —Journal surfaces 3 Non-linear 3 5,0

Aligned 0 —

Table 5.4.4 Surface inspection acceptance for crankshaft forgings – Allowable number and size of indications ina reference area of 225 cm2

Allowable disc shape Allowable length ofaccording to Distance indication,

Type of forging Zone Gain Size (DGS), mm see Notemm

I d ≤ 2,0 —Crank shaft II d ≤ 3,0 ≤10

III d ≤ 4,0 ≤15

NOTEFor accumulations of two or more isolated indications which are subjected to registration, the minimum distance between two neighbouring indications is to be at least the length of the larger indication. This applies to the distance in axial direction as to the distance in depth.Isolated indications with less distance are to be determined as one single indication.

Table 5.4.5 Ultrasonic acceptance criteria for crankshafts

Steel Forgings

5.4 Heat treatment

5.4.1 Except as provided in 5.4.4 and 5.4.5, forgingsmay be either normalised and tempered or quenched andtempered in accordance with the approved specification. Thetempering temperature is to be not less than 550°C.

5.4.2 Where forgings are machined prior to heat treat-ment, the allowance left for final machining is to be sufficientto remove the decarburised surface material, taking intoaccount any bending or distortion which may occur.

5.4.3 When the teeth of a pinion or gear wheel are to besurface hardened, i.e, carburised, nitrided or induction hardened, the proposed specification together with details ofthe process and practice are to be submitted for approval.For purposes of initial approval, the gear manufacturer isrequired to demonstrate by test that the surface hardening ofthe teeth is uniform and of the required depth and that it doesnot impair the soundness and quality of the steel.

5.4.4 Where induction hardening of nitriding is to becarried out after machining of the gear teeth, the forgings areto be heat treated at an appropriate stage to a condition suitable for this subsequent surface hardening.

5.4.5 Forgings for gears which are to be carburised afterfinal machining are to be supplied in either the fully annealedor the normalised and tempered condition, suitable for subse-quent machining and carburising.

5.5 Mechanical tests for through hardened,induction hardened or nitrided forgings

5.5.1 At least one tensile test specimen is to be takenfrom each forging in carbon or carbon-manganese steel, andat least one tensile test specimen from forgings in alloy steel.Sufficient test material is to be provided for this purpose andthe test specimens are to be taken as follows:(a) For pinion forgings where the finished diameter of the

toothed portion exceeds 200 mm, tests are to be takenin a tangential direction and adjacent to the toothedportion (test position B in Fig. 5.5.1). Where the dimen-sions preclude the preparation of tests from this position,tests in a tangential direction are to be taken from theend of the journal (test position C in Fig. 5.5.1). If,however, the journal diameter is 200 mm or less, testsare to be taken in a longitudinal direction (test position Ain Fig. 5.5.1). Where the finished length of the toothedportion exceeds 1250 mm, tests are to be taken fromeach end.

(b) For small pinion forgings where the finished diameter ofthe toothed portion is 200 mm or less, tests are to betaken in a longitudinal direction (test position A inFig. 5.5.1).

(c) For gear wheel forgings, tests are to be taken in atangential direction (from one of the test positions B inFig. 5.5.2).

(d) For gear wheel rim forgings, tests are to be taken in atangential direction (from one of the test positions A inFig. 5.5.3). Where the finished diameter exceeds 2500 mmor the mass (as heat treated but excluding test material)exceeds 3 tonnes, tests are to be taken from two

diametrically opposite positions (test positions A inFig. 5.5.3).

(e) For pinion sleeve forgings, tests are to be taken in atangential direction (from one of the test positions C inFig. 5.5.4). Where the finished length exceeds 1250 mm,tests are to be taken from each end.


Chapter 5Section 5


d

Test position B(tangential)


L

D



L = length of toothed portion, in metresD = diameter of toothed portion, in metresd = journal diameter, in metres

Fig. 5.5.1 Test positions for forgings for gearing

Test position B (tangential)

Fig. 5.5.2 Test position B

Test position A (tangential)

Test position A (tangential)

Fig. 5.5.3 Test position A

Steel Forgings

5.5.2 As an alternative to 5.5.1, small forgings may bebatch tested in accordance with 1.6.4 provided that, in addition, hardness tests are carried out on each forging.

5.5.3 Tables 5.5.1 to 5.5.3 give the minimum require-ments for yield stress and elongation corresponding todifferent strength levels, but it is not intended that theseshould necessarily be regarded as specific grades. Thestrength levels have been given in multiples of 40 N/mm2, or50 N/mm2 in the case of alloy steels, to facilitate interpolationfor intermediate values of specified minimum tensile strength.

5.5.4 Forgings may be supplied to any specified minimum tensile strength selected within the general limitsdetailed in Tables 5.5.1 to 5.5.3.

5.5.5 The results of all tensile tests are to comply with therequirements of Table 5.5.1, 5.5.2 or 5.5.3, appropriate to thespecified minimum tensile strength. Unless otherwise agreed,the specified minimum tensile strength is to be not less than800 N/mm2 (800–950 N/mm2 acceptance range) for inductionhardened or nitrided gear forgings.



<600 70≥600 <900 100≥900 120


Chapter 5Section 5




Fig. 5.5.4 Test position C

Yield Elongation onTensile strength

stress 5,65 So HardnessN/mm2

N/mm2 % minimum Brinell(see Note)

minimum Rims Wheels

400–520 200 26 22 110–150440–560 220 24 21 125–160480–600 240 22 19 135–175520–640 260 21 18 150–185560–680 280 20 17 160–200600–750 300 18 15 175–215640–790 320 17 14 185–230680–830 340 16 14 200–240720–870 360 15 13 210–250760– 910 380 14 12 225–265


NOTEWhen the specified minimum tensile strength exceeds 700 N/mm2 forgings are to be supplied only in the quenched and tempered condition.

Table 5.5.1 Mechanical properties for acceptancepurposes: carbon-manganese steelsfor gear wheel and rim forgings

Yield Elongation onTensile strength stress 5,65 So Hardness

N/mm2 N/mm2 % minimum Brinellminimum

Rims Wheels

600–750 330 18 16 175–215650–800 355 17 15 190–235700–850 380 16 14 205–245750–900 405 15 13 215–260800–950 430 14 12 235–275850–1000 455 13 11 245–290


Table 5.5.2 Mechanical properties for acceptancepurposes: alloy steel gear wheel andrim forgings – Normalised andtempered

Yield Elongation onTensile strength stress 5,65 So Hardness

N/mm2 N/mm2 % minimum Brinell(see Notes 1 minimum

and 2) (see Note 2) A B C

600–750 420 18 16 14 175–215650–800 450 17 15 13 190–235700–850 480 16 14 12 205–245750–900 530 15 13 11 215–260800–950 590 14 12 10 235–275850–1000 640 13 11 9 245–290900–1050 690 13 11 9 260–310950–1100 750 12 10 8 275–3301000–1150 810 12 10 8 290–3401050–1200 870 11 9 7 310–365

Column A is applicable to tests from gear rims and to longitudinaltests from pinions.Column B is applicable to tests from gear wheels and to tangen-tial tests from pinions.Column C is applicable to tests from pinion sleeves.


NOTES1. For gear wheel and rim forgings the specified minimum tensile

strength is not to exceed 850 N/mm2.2. For carburised gear forgings the requirements for minimum

yield stress and maximum tensile strength are not applicable.

Table 5.5.3 Mechanical properties for acceptancepurposes: alloy steel gear forgings –Quenched and tempered

Steel Forgings

5.5.7 Hardness tests are to be carried out on all forgingsafter completion of heat treatment and prior to machining thegear teeth. The hardness is to be determined at four positionsequally spaced around the circumference of the surface whereteeth will subsequently be cut. Where the finished diameterof the toothed portion exceeds 2500 mm, the number of testpositions is to be increased to eight. Where the width of agear wheel rim forging exceeds 1250 mm, the hardness is tobe determined at eight positions at each end of the forging.

5.5.8 For small gear forgings which are batch tested, atleast one hardness test is to be carried out on each forging.

5.5.9 The results of all hardness tests are to comply withthe appropriate requirements of Tables 5.5.1 to 5.5.3. Thedifference between the highest and lowest values on any oneforging is not to exceed the following:

Specified minimum Difference in hardnesstensile strength (Brinell number)(N/mm2)<600 25≥600 <900 35≥900 42

5.5.10 On nitrided or induction hardened components,hardness tests are also to be made on the teeth when surfacehardening and grinding have been completed. The results areto comply with the approved specification.

5.6 Mechanical tests for carburised forgings

5.6.1 Sufficient test material is to be provided for prelim-inary tests at the forge and for final tests after completion ofcarburising. For this purpose, duplicate sets of test materialare to be taken from positions as detailed in 5.5.1, exceptthat, irrespective of the dimensions or mass of the forging,tests are required from one position only, and in the case offorgings with integral journals are to be cut in a longitudinaldirection. The test material which is to be used for measure-ments of case depth, hardness, grain size and residualaustenite as well as mechanical properties is to be machined

to a coupon of diameter of or 30 mm, whichever is less,

where D is the finished diameter of the toothed portion.

5.6.2 For small forgings, where a system of batch testing is adopted, the test material may be prepared fromsurplus steel from the same cast provided that the forgingreduction approximates to that of the actual gear forgings.The test samples are to be correctly identified and heattreated with the forgings they represent.

5.6.3 For preliminary tests at the forge, one set of test material is to be given a blank carburising and heat treatment cycle simulating that which will be subsequently applied to the forgings.

5.6.4 For final acceptance tests, the second set of testmaterial is to be blank carburised and heat treated togetherwith the forgings which it represents.

D4

5.6.5 At the discretion of the forgemaster or gear manufacturer, test samples of larger cross-section than in5.6.1 may be either carburised or blank carburised, but theseare to be machined to the required diameter prior to the finalquenching and stress relieving heat treatment.

5.6.6 At least one tensile specimen is to be prepared fromeach sample of test material.

5.6.7 Unless otherwise agreed, the specified minimumtensile strength is to be not less than 750 N/mm2, and theresults of all tensile tests are to comply with the requirementsgiven in Table 5.5.3.

5.6.8 Where it is proposed to adopt alternatives to therequirements of 5.6.1 to 5.6.7, full details are to be submittedto the Surveyor for consideration.


5.7.1 Magnetic particle or liquid penetrant testing is to becarried out on the teeth of all surface hardened forgings. Thisexamination may also be requested on the finished machinedteeth of through hardened gear forgings.

5.7.2 The manufacturer is to carry out an ultrasonicexamination of all forgings where the finished diameter of thesurfaces, where teeth will be cut, is in excess of 200 mm, andis to provide the Surveyor with a signed statement that suchinspection has not revealed any significant internal defects.

5.7.3 On gear forgings where the teeth have been surfacehardened, additional test pieces may be required to beprocessed with the forgings and subsequently sectioned todetermine the depth of the hardened zone. These tests are tobe carried out at the discretion of the Surveyor, and for induction or carburised gearing the depth of the hardened zoneis to be in accordance with the approved specification. Fornitrided gearing, the full depth of the hardened zone, (i.e., depthto core hardness), is to be not less than 0,5 mm and the hardness at a depth of 0,25 mm is to be not less than 500 HV.

■ Section 6Forgings for turbines

6.1 Scope

6.1.1 Provision is made in this Section for ferritic steelforgings for turbine rotors, discs and spindles, turbine-drivengenerator rotors and compressor rotors.

6.1.2 Plans for rotor forgings are to state whether therotor is intended for propulsion or auxiliary machinery and theshaft power of auxiliary turbines. In the case of a rotor whichis to be tested for thermal stability, the maximum operatingtemperature and the proposed test temperature are also tobe stated.




Steel Forgings

6.1.3 Specifications of alloy steel forgings giving theproposed chemical composition, heat treatment and mechanicalproperties are to be submitted for approval with the plans ofthe components.

6.1.4 Where it is proposed to use rotors of weldedconstruction, the compositions of the steels for the forgingsare to be submitted for special consideration, together withdetails of the proposed welding procedure. Welding proceduretests may be required.

6.2 Manufacture

6.2.1 Forgings are to be manufactured in accordancewith the requirements of Section 1, except that for rotors theforging reduction is to be not less than 2,5 to 1. Where anupsetting operation is included in the manufacturing proce-dure, the above requirement applies to the cross-sectionalarea of the upset bloom and not to that of the ingot.


6.3.1 The chemical composition of ladle samples is tocomply with 3.2.1 for carbon and carbon-manganese steelsand 1.4.3 for alloy steels.

6.4 Heat treatment

6.4.1 Forgings are to be supplied in the heat treatedcondition, and the thermal treatment at all stages is to besuch as to avoid the formation of hair-line cracks. At a suitable stage of manufacture, the forgings are to be reheatedabove the upper critical point to refine the grain, cooled in anapproved manner and then tempered to produce the desiredmechanical properties.

6.4.2 Where forgings receive their main heat treatmentbefore machining, they are to be stress relieved after roughmachining. Forgings which are heat treated in the roughmachined condition need not be stress relieved provided thatthey have been slowly cooled from the tempering tempera-ture.

6.4.3 The tempering and stress relieving temperaturesare to be not less than 550°C for carbon and carbon-manganese steels, and not less than 600°C for alloy steels.The holding times and subsequent cooling rates are to besuch that the forging in its final condition is free from harmfulresidual stresses.

6.4.4 Details of the proposed heat treatment for rotors ofwelded construction are to be submitted for approval.


6.5.1 At least one tensile test specimen, cut in a longitudinal direction, is to be taken from each rotor forging.For forgings exceeding both 3 tonnes in mass and 2000 mmin length, tests are to be taken from each end.

6.5.2 For rotor forgings of all main propulsion machineryand of auxiliary turbines exceeding 1100 kW, tangential and,where the dimensions permit, radial tensile tests are to betaken from the end of the body corresponding to the top endof the ingot, see Fig. 5.6.1.

6.5.3 For each turbine disc, at least one tensile test specimen is to be cut in a tangential direction from materialat the hub, see Fig. 5.6.2.

6.5.4 For the tests required by 6.5.1 to 6.5.3, sufficienttest material is to be left on each forging and is not to beremoved until all heat treatment, including stress relieving, hasbeen completed. In this connection, a thermal stability testdoes not form part of the heat treatment of a turbine forging.Any excess test material is not to be completely severed froma forging until all the mechanical tests have been completedwith satisfactory results.


Chapter 5Section 6



Test position C (radial)

L

Top end of ingot Test position A(longitudinal)

Fig. 5.6.1 Test positions for turbine rotor forgings


Test position C(tangential at bore)

Test position C(tangential at bore)Test position B

(tangential)

Fig. 5.6.2 Test positions for turbine disc forgings

Steel Forgings

6.5.5 Tables 5.6.1 and 5.6.2 give the minimum require-ments for yield stress, elongation and reduction of areacorresponding to different strength levels, but it is notintended that these should necessarily be regarded asspecific grades. The strength levels have been given in multiples of 40 N/mm2, or 50 N/mm2 for alloy steels, to facilitate interpolation for intermediate values of specified minimum tensile strength.

6.5.6 Forgings may be supplied to any specified minimum tensile strength selected within the general limitsdetailed in Table 5.6.1 or Table 5.6.2.

6.5.7 The results of all tensile tests are to comply with therequirements of Table 5.6.1 or Table 5.6.2 appropriate to thespecified minimum tensile strength. For monobloc rotor forgings, the specified minimum tensile strength is not toexceed 800 N/mm2.


6.6.1 The end faces of the body of rotor forgings and theend faces of the boss and the bore surface of each turbinedisc are to be machined to a fine smooth finish for visual andmagnetic particle examination.

6.6.2 The manufacturer is to carry out an ultrasonicexamination of each forging and is to provide the Surveyorwith a signed statement that such inspection has not revealedany significant internal defects.

6.6.3 Rotor forgings for propulsion machinery and forauxiliary turbines exceeding 1100 kW are to be hollow boredfor internal examination. The surface of the bore is to have afine smooth finish and is to be examined by means of an optical instrument of suitable magnification. Where the boresize permits, magnetic particle examination is also to becarried out. These examinations are to be confirmed by theSurveyor. Alternatively, an approved method of ultrasonicexamination may be accepted instead of hollow boring.Details of the proposed method of ultrasonic examination areto be submitted for special consideration.


Chapter 5Section 6


Elongation ReductionTensile Yield stress 5,65 So of area

strength N/mm2% minimum % minimum

N/mm2 minimumA B C A B C

400–520 200 26 22 18 50 40 35440–560 220 24 21 17 50 40 35480–600 240 22 19 15 45 35 30520–640 260 21 18 14 45 35 30560–680 280 20 17 13 40 30 25600–720 300 18 15 12 40 30 25

NOTESColumns A are applicable to longitudinal tests from rotor andspindle forgings.Columns B are applicable to tangential tests from rotor forgings.Columns C are applicable to radial tests from rotor forgings.Intermediate values may be obtained by interpolation.

Table 5.6.1 Mechanical properties for acceptance purposes: carbon-manganese steel forgings forturbines – Normalised and tempered

Yield stress Yield stress Elongation on ReductionTensile strength N/mm2 minimum N/mm2 minimum 5,65 So of area

N/mm2 Normalised Quenched and % minimum %minimum(see Note) and tempered tempered

A B C A B C

500 – 650 275 — 22 20 18 50 40 35550 – 700 300 — 20 18 16 50 40 35600 – 750 330 410 18 16 14 50 40 35650 – 800 355 450 17 15 13 50 40 35

700 – 850 385 490 16 14 12 45 35 30750 – 900 — 530 15 13 11 45 35 30800 – 950 — 590 14 12 10 45 35 30850 – 1000 — 640 13 11 9 40 30 25

900 – 1050 — 690 13 11 9 40 30 25950 – 1100 — 750 12 10 8 40 30 25

1000 – 1150 — 810 12 10 8 40 30 25

NOTESColumns A are applicable to longitudinal tests from rotor and spindle forgings.Columns B are applicable to tangential tests from rotor and spindle forgings, and to tangential tests from discs – test position B in Fig. 5.6.2.Columns C are applicable to radial test from rotor forgings and to tangential tests from discs – test position C in Fig. 5.6.2.Intermediate values may be obtained by interpolation.

Table 5.6.2 Mechanical properties for acceptance purposes: alloy steel forgings for turbines – Quenched andtempered or normalised and tempered

Steel Forgings

6.7 Thermal stability tests

6.7.1 Thermal stability tests after heat treatment and roughmachining of the turbine rotors, referred to in the relevant Rulesdealing with design and construction, are to be undertaken inproperly constructed furnaces, using accurate and reliablemeasuring equipment. Each test is to be carried out in accordance with the following recommended procedure:(a) Five bands are to be machined concentric with the axis of

rotation. Two of these are to be reference bands and are tobe positioned at or near the locations of the bearings. Theremaining three bands are to be test bands located one asnear as possible to the mid-length, and the other two neareach end of the body. Where the length of a rotor is suchthat five bands cannot be provided, alternative proposalsare to be submitted to the Surveyor for his approval.

(b) Four positions, 90° apart, are to be stamped A, B, C andD on the coupling end of the rotor.

(c) The whole of the body, and as much of the shaft at eitherend as will include the positions of the glands, is to beenclosed in the furnace. In the case of a rotor having anoverhung astern wheel, the astern wheel is also to beenclosed in the furnace during the first test.

(d) The rotor is to be rotated at a uniform and very low speed.(e) The deflections at all bands are to be recorded at the A,

B, C and D positions. Initial cold readings are to be takenprior to heating.

(f) The rotor is to be heated uniformly and slowly.Temperatures are to be recorded continuously at thesurface of the rotor and, if practicable, in the bore at themid-length of the body. In no circumstances is the surfacetemperature to exceed the temperature at which the rotorwas tempered. During heating, the rate of rise of temper-ature is to be such as to avoid excessive temperaturegradients in the rotor.

(g) The maximum or holding temperature is to be not lessthan 28°C above the maximum operating temperature ofthe rotor. For the purposes of the test, the holding periodis to start when the rotor has attained a uniform andspecified temperature. The rotor is to be held under thespecified temperature conditions until not less than threeconsecutive hourly readings of deflections show the radialeccentricity to be constant within 0,006 mm on all testbands.

(h) The turbine rotor is to be rotated during cooling until thetemperature is not more than 100°C. The rate of coolingis to be such as to avoid excessive temperature gradientsin the rotor.

(j) Final cold readings are to be taken.

6.7.2 The movements of the axis of the rotor in relationto the reference bands are to be determined from polar plotsof the deflection readings. The radial movement of the shaftaxis, as determined by the difference between the final hotand the final cold movements, is not to exceed 0,025 mm onany one band. As verification that test equipment and conditions are satisfactory, it is required that similar determi-nations of differences between initial cold and final coldmovements do not exceed 0,025 mm on any one band.

6.7.3 If the results of the test on a rotor fail to meet eitheror both of the requirements in 6.7.2, the test may be repeatedif requested by the maker and agreed by the Surveyor. In thecase of a rotor failing to meet the requirements of a thermalstability test, the rotor is deemed unacceptable. Proposals forthe rectification of thermal instability of a rough machinedrotor are to be submitted for special consideration.

■ Section 7Forgings for boilers, pressurevessels and piping systems

7.1 Scope

7.1.1 Provision is made in this Section for carbon-manganese and low alloy steel forgings intended for use inthe construction of boilers, pressure vessels and pipingsystems where the design temperature is not lower than 0°C.

7.1.2 In addition to specifying mechanical properties atambient temperature for the purposes of acceptance testing,these requirements give details of appropriate mechanicalproperties at elevated temperatures to be used for designpurposes.

7.1.3 Forgings used in the construction of equipment forthe containment of liquefied gases are to comply with therequirements of Section 8, except for those used in pipingsystems, where the design temperature is not lower than 0°C.Forgings for other pressure vessels and piping systems, wherethe use of steels with guaranteed impact properties at lowtemperatures is required, are also to comply with Section 8.


7.2.1 The chemical composition of ladle samples is tocomply with the appropriate requirements of Table 5.7.1.

7.3 Heat treatment

7.3.1 Carbon-manganese steel forgings are to benormalised, normalised and tempered or quenched andtempered.

7.3.2 Alloy steel forgings are to be normalised andtempered or quenched and tempered.

7.3.3 No forging is to be fully heat treated more than twice.


7.4.1 Except as provided in 7.4.2 and 7.4.4, at least onetensile test is to be taken from each forging and, where thedimensions and shape allow, the test specimen is to be cut inthe longitudinal direction.




Steel Forgings

7.4.2 On seamless drums and headers which are initiallyforged with open ends, test material is to be provided at eachend of each forging. Where forged with one solid end, testmaterial is to be provided at the open end only. Except wherethe ends are to be subsequently closed by forging, the testmaterial is not to be removed until heat treatment has beencompleted. Where the ends are to be closed, rings of testmaterial are to be cut off prior to the closing operation andare to be heat treated with the finished forging. In all cases,the test specimens are to be cut in the circumferential direction.

7.4.3 Unless otherwise agreed, tensile test specimensare to be taken with their axis at approximately 12,5 mmbelow the surface of the forging.

7.4.4 Small forgings may be batch tested in accordancewith 1.6.4 provided that hardness tests are carried out oneach forging. In such cases, the mass of each forging is notto exceed 1 tonne and that of the batch is not to exceed10 tonnes and the hardness values are to accord with Table 5.7.2.


Chapter 5Section 7


Diameter or ElongationType of steel equivalent

Yield stress Tensile strengthon 5,65 So

Hardness

thickness mmN/mm2 N/mm2

% minimumBrinell

≤100 215410–530 20 110–155

>100 ≤500 205

≤100 245Carbon-manganese 460–580 18 130–170not specifically >100 235fine grained

≤100 265490–610 16 140–180

>100 255

≤100 235410–530 20 110–155

>100 ≤250 220

≤100 275Carbon-manganese, 460–580 18 130–170

fine grained >100 ≤250 255

≤100 305490–610 16 140–180

>100 ≤250 280

Alloy steel1Cr1/2Mo – 275 440–590 19 110–160

21/4Cr1Mo – 275 490–640 18 140–185


Tensile Chemical composition of ladle samples %

Type of steel strength CSi Mn

P SAl Residual elementsN/mm2

max. max. max.

410–530 0,20 0,50–1,20 Ni 0,40 max.Carbon- Cr 0,25 max.manganese 460–580 0,23 0,10–0,40 0,80–1,40 0,030 0,025 (See Notes Mo 0,10 max.

1 and 3) Cu 0,30 max.490–610 0,25 0,90–1,70

Total 0,80 max.

Cr Mo

Alloy steel

1Cr1/2Mo 440–590 0,18 0,85–1,15 0,45–0,650,15–0,40 0,40–0,70 0,030 0,025 0,020 max.

21/4 Cr1Mo 490–640 0,15 (See Note 2) 2,0–2,5 0,90–1,20

NOTES1. Fine grained steels are to contain:

aluminium (acid soluble) 0,015% min. oraluminium (total) 0,018% min.

2. For alloy steels, aluminium (acid soluble) 0,020% max.The determination of the aluminium (total) content is acceptable provided the above value is not exceeded.

3. Niobium may be used as a grain refiner in place of aluminium, in which case the content is to be in the range 0,01% to 0,06%.


Steel Forgings

7.4.5 If required by the Surveyors or by the Fabricators,test material may be given a simulated stress relieving heattreatment prior to the preparation of the test specimens. Thishas to be stated on the order, together with agreed details ofthe simulated heat treatment and the mechanical propertieswhich can be expected.

7.4.6 Except as provided in 7.4.7, the results of all tensiletests are to comply with the requirements given in Table 5.7.2appropriate to the specified minimum tensile strength.

7.4.7 Where tests are taken at a depth greater than12,5 mm from the surface or where they are taken in a transverse direction, the mechanical properties which can beexpected are to be agreed.

7.4.8 On seamless drums and headers where tests aretaken from each end, the variation in tensile strength is not toexceed 70 N/mm2.

7.4.9 For small batch-tested forgings, the hardnessvalues are to comply with the requirements of Table 5.7.2appropriate to the specified minimum tensile strength. If forgings of more than one thickness are to be supplied fromone cast, then the test is to be made on the thickest forging.


7.5.1 Non-destructive testing is to be carried out inaccordance with the requirements of the approved forgingdrawing and specification, or as otherwise agreed betweenthe manufacturer, purchaser and Surveyor.

7.6 Pressure tests

7.6.1 Where applicable, pressure tests are to be carriedout in accordance with the requirements of the relevant Rules.


7.7.1 Nominal values for the minimum lower yield or 0,2 per cent proof stress at temperatures of 50°C and higherare given in Table 5.7.3. These values are intended for designpurposes only, and verification is not required except for materials complying with National or proprietary specificationswhere the elevated temperature properties used for designpurposes are higher than those given in Table 5.7.3.


Chapter 5Section 7


Diameter orTensile Nominal minimum lower yield or 0,2% proof stress N/mm2

Type of steelequivalent

strengththickness

N/mm2Temperature °C

mm 50 100 150 200 250 300 350 400 450 500 550 600

≤100 196 192 188 181 168 150 142 138 136 — – —410–530

>100 183 178 175 170 162 150 142 138 136 — — —

Carbon-manganese ≤100 227 222 218 210 194 176 168 162 158 — — —not specifically 460–580fine grained >100 212 206 203 197 188 176 168 162 158 — — —

≤100 245 240 236 227 210 192 183 177 172 — — —490–610

>100 229 222 219 212 203 192 183 177 172 — — —

≤100 222 215 204 188 171 152 141 134 130 — — —410–530

>100 207 200 190 175 164 152 141 134 130 — — —

≤100 262 251 236 217 198 177 167 158 153 — — —Carbon-manganese 460–580

fine grained >100 244 233 220 202 190 177 167 158 153 — — —

≤100 286 272 256 234 213 192 182 173 168 — — —490–610

>100 266 253 238 218 205 192 182 173 168 — — —

Alloy steel1Cr1/2Mo — 410–560 254 241 224 213 197 184 170 162 157 151 146 145

21/4 Cr1Mo — 490–640 268 261 253 245 236 230 224 218 205 189 167 145

Table 5.7.3 Mechanical properties for design purposes

Steel Forgings

7.7.2 Where verification is required, at least one tensiletest at the proposed design or other agreed temperature is tobe made on each forging or each batch of forgings. The testspecimen is to be taken from material adjacent to that usedfor tests at ambient temperature, and the test procedure is tobe in accordance with the requirements of Chapter 2. Theresults of all tests are to comply with the requirements of theNational or proprietary specification.


■ Section 8Ferritic steel forgings for lowtemperature service

8.1 Scope

8.1.1 The requirements for carbon-manganese and nickelsteels suitable for low temperature service are detailed in thisSection. They are applicable to all forgings used for theconstruction of cargo tanks, storage tanks and process pressure vessels for liquefied gases and, where the designtemperature is less than 0°C, to forgings for the piping systems.

8.1.2 The requirements are also applicable to forgings forother pressure vessels and pressure piping systems wherethe use of steels with guaranteed impact properties at lowtemperatures is required.

8.1.3 In all cases, details of the proposed chemicalcomposition, heat treatment and mechanical properties areto be submitted for approval.

8.1.4 In addition to the steels in this Section, theaustenitic stainless steels detailed in Section 9 may also beused for low temperature applications.


8.2.1 The chemical composition of ladle samples is, ingeneral, to comply with the requirements given in Table 5.8.1.

8.3 Heat treatment

8.3.1 Forgings are to be normalised, normalised andtempered or quenched and tempered in accordance with theapproved specification.


8.4.1 At least one tensile and three Charpy V-notchimpact test specimens are to be taken from each forging oreach batch of forgings. Where the dimensions and shapeallow, the test specimens are to be cut in a longitudinal direction.

8.4.2 The impact tests are to be carried out at a temperature appropriate to the type of steel and for theproposed application. Where forgings are intended for shipsfor liquefied gases, the test temperature is to be in accordance with the requirements given in Table 3.6.3 inChapter 3.

8.4.3 The results of all tensile tests are to comply with theapproved specification.

8.4.4 The average energy values for impact tests are alsoto comply with the approved specification and generally withthe requirements of Ch 3,6. One individual value may be lessthan the required average value provided that it is not less than70 per cent of this value. See Ch 2,1.4 for re-test procedures.




Table 5.7.4 Mechanical properties for designpurposes: estimated average valuesfor stress to rupture in 100 000 hours(units N/mm2)

Grades of steel

Temperature°C Carbon-

manganese1 Cr 1/2 Mo 21/4 Cr 1Mo

380 227 — —390 203 — —400 179 — —410 157 — —420 136 — —

430 117 — —440 100 — —450 85 290 —460 73 262 —470 63 235 210

480 55 208 186490 — 181 165500 — 155 145510 — 129 128520 — 103 112

530 — 80 98540 — 62 84550 — 49 72560 — 42 61570 — 36 49

580 — 32 —590 — 29 —

Steel Forgings


8.5.1 Non-destructive testing is to be carried out inaccordance with the requirements of the approved forgingdrawing and specification, or as otherwise agreed betweenthe manufacturer, purchaser and Surveyor.

8.6 Pressure tests

8.6.1 When applicable, pressure tests are to be carriedout in accordance with the requirements of the relevant Rules.

■ Section 9Stainless steel forgings

9.1 General

9.1.1 Forgings in austenitic and duplex stainless steels areacceptable for use in the construction of cargo tanks, storagetanks and piping systems for chemicals and liquefied gases.They may also be accepted for elevated temperature service inboilers.

9.1.2 Where it is proposed to use forgings in these typesof steels, details of the chemical composition, heat treatmentand mechanical properties are to be submitted for approval.These are to comply, in general, with the requirements of Ch 3,7 for austenitic steel plates.



9.2.2 Consideration will be given to the use of steelswhose compositions are outside the scope of Table 5.9.1.

9.3 Heat treatment

9.3.1 All materials are to be supplied in the solutiontreated condition.


9.4.1 Tensile test specimens are to be taken inaccordance with the appropriate requirements of 1.7.

9.4.2 The results of all tensile tests and impact tests areto comply with the requirements of Table 5.9.2 or theapproved specification.

9.4.3 For austenitic stainless steel forgings, impact testsmay be omitted subject to prior agreement with LR.




Grade of steelC Si Mn Ni P S Residual Grain refiners %% % % % % % elements % Al Other

LT–AH (AH40) (See Note)LT–DH (DH40) 0,18 0,40 0,035 0,030LT–EH (EH40) max. max. max. max. Cu 0,35 max.

0,50 0,90–1,60 Cr 0,20 max. Nb 0,02 – 0,05max. Mo 0,08 max. V 0,03 – 0,10

LT–FH (FH40) 0,16 0,80 0,025 Ti 0,02 max.max. max. max. Total 0,60 max.

11/2Ni 0,18 0,30–1,50 1,30–1,70 Total max. 0,020 min.

31/2Ni 0,15 3,20–3,80 Cu 0,35 max. Acid solublemax. 0,025 Cr 0,25 max. 0,015 min.

0,10 – 0,35 max. Mo 0,08 max.5Ni 0,12 0,30–0,90 4,70–5,30 0,020

max. max. Total 0,60 max.

9 Ni 0,10 8,50–10,0max.

Table 5.8.1 Chemical composition of ferritic steel forgings

NOTEThe steel is to contain aluminium, niobium, vanadium or other suitable grain refining elements, either singly or in any combination. When usedsingly, the steel is to contain the specified minimum content of the grain refining element. When used in combination, the specified minimumcontent of each element is not applicable.


Chapter 5Section 9


Table 5.9.1 Chemical composition of stainless steel forgings

Chemical composition % (see Note)Type ofsteel

C Si Mn S P Cr Mo Ni Others

Austenitic

304L 0,03 18,0–20,0 – 8,0–13,0 —

304 0,08 18,0–20,0 – 8,0–11,0 —

316L 0,03 16,0–18,0 2,0–3,0 10,0–15,0 —

316 0,08 1,00 2,00 0,030 0,045 16,0–18,0 2,0–3,0 10,0–14,0 —

317 0,08 18,0–20,0 3,0–4,0 11,0–15,0 —

Nb347 0,08 17,0–20,0 – 9,0–13,0 ≥ 10 x C

≤ 1,10

Duplex

UNS S 0,03 1,00 2,00 0,020 0,030 21,0–23,0 2,5–3,5 4,5–6,5 N31803 0,08–0,20

UNS S N32750 0,03 0,80 1,20 0,020 0,035 24,0–26,0 3,0–5,0 6,0–8,0 0,24–0,32

Cu 0,50

NOTEWhere a single value is shown (and not a range of values), the value is to be taken as maximum.

Charpy V-notch impact testsTensile strength 1,0% proof stress Elongation Reduction

Type of steel N/mm2 N/mm2 on 5,65 So of area Test Averageminimum minimum % minimum % minimum temperature energy

°C J minimum

Austenitic

304L 485 170

304 515 205

316L 485 170

316 515 205 30 50 –196 41

317 515 205

347 515 205

Duplex

UNS S 31803 620 450 25 45–20 41

UNS S 32750 800 550 15 40

Table 5.9.2 Mechanical properties for acceptance purposes: stainless steel forgings

Steel Forgings


9.5.1 Where austenitic stainless steel forgings areintended for service at elevated temperatures, the nominalvalues for the minimum one per cent proof stress at temper-atures of 100°C and higher given in Table 5.9.3 may be usedfor design purposes. Verification of these values is notrequired except for material complying with a National orproprietary specification in which the elevated temperatureproperties proposed for design purposes are higher thanthose given in Table 5.9.3.


9.6.1 Non-destructive examination is to be carried out inaccordance with the requirements of the approved forgingdrawing and specification or as otherwise agreed betweenthe manufacturer, purchaser and Surveyor.

9.7 Corrosion tests

9.7.1 Where corrosive conditions are anticipated inservice, for grades 304, 316 and 317 intergranular corrosiontests are required in accordance with Ch 2,8.1. Such testsmay also be required for grades 304L, 316L and 347.

9.7.2 Where corrosive conditions are anticipated inservice, for duplex stainless grades pitting corrosion tests arerequired in accordance with ASTM G48 Method C. For UNSS 31803 duplex stainless steels the test temperature is to be25°C. Following the test, no pitting corrosion is to beobserved at 20x magnification. The use of a weight lossmethod may be accepted subject to special consideration.


Chapter 5Section 9


Nominal 1% proof stress (N/mm2) at a temperature ofGrade

100°C 150°C 200°C 250°C 300°C 350°C 400°C 450°C 500°C 550°C 600°C 650°C 700°C

304L 168 150 137 128 122 116 110 108 106 102 100 96 93

316L 177 161 149 139 133 127 123 119 115 112 110 107 105

316LN 238 208 192 180 172 166 161 157 152 149 144 142 138

321 192 180 172 164 158 152 148 144 140 138 135 130 124

347 204 192 182 172 166 162 159 157 155 153 151 — —

Table 5.9.3 Mechanical properties for design purposes: austenitic stainless steels

Section


2 Seamless pressure pipes

3 Welded pressure pipes

4 Ferritic steel pressure pipes for low temperatureservice

5 Austenitic stainless steel pressure pipes

6 Boiler and superheater tubes


1.1 Scope

1.1.1 This Section gives the general requirements forboiler tubes, superheater tubes and pipes intended for use inthe construction of boilers, pressure vessels and pressurepiping systems.

1.1.2 In addition to specifying mechanical properties forthe purpose of acceptance testing, these requirements givedetails of appropriate mechanical properties at elevatedtemperatures to be used for design purposes.

1.1.3 Except for pipes for Class III pressure systems (asdefined in the relevant Rules), all pipes and tubes are to bemanufactured and tested in accordance with the requirementsof Chapters 1 and 2, the general requirements of this Sectionand the appropriate specific requirements given in Sections 2,3, 4, 5 and 6.

1.1.4 Steels intended for the piping systems for liquefiedgases where the design temperature is less than 0°C are tocomply with the specific requirements of Section 4 or 5.

1.1.5 As an alternative to 1.1.3 and 1.1.4, pipes or tubeswhich comply with National or proprietary specifications maybe accepted provided that these specifications give reason-able equivalence to the requirements of this Chapter oralternatively are approved for a specific application. Generally,survey and certification are to be carried out in accordancewith the requirements of Chapter 1.

1.1.6 At the discretion of the Surveyor, a modified testing procedure may be adopted for small quantities ofmaterials. In such cases, these may be accepted on themanufacturer’s declared chemical composition and hardnesstests or other evidence of satisfactory properties.

1.1.7 Pipes for Class III pressure systems are to bemanufactured and tested in accordance with the requirementsof an acceptable National specification. The manufacturer’stest certificate will be acceptable and is to be provided foreach consignment of material. Forge butt welded pipes arenot acceptable for oil fuel systems, heating coils in oil tanks,primary refrigerant systems and other applications where thepressure exceeds 4,0 bar (4,1 kgf/cm2).

1.2 Manufacture

1.2.1 Pipes for Class I and II pressure systems, boiler andsuperheater tubes are to be manufactured at works approvedby Lloyd’s Register (hereinafter referred to as ‘LR’). The steelused is to be manufactured and cast in ingot moulds or by anapproved continuous casting process as detailed in Ch 3,1.4.

1.2.2 Unless a particular method is requested by thepurchaser, pipes and tubes may be manufactured by any ofthe following methods:• Hot finished seamless.• Cold finished seamless.• Electric resistance or induction welded.• Cold finished electric resistance or induction welded.• Electric fusion welded.

1.2.3 Care is to be taken during manufacture that thepipe or tube surfaces coming in contact with any non-ferrousmetals or their compounds are not contaminated to such anextent as could prove harmful during subsequent fabricationand operation.

1.3 Quality

1.3.1 All pipes and tubes are to have a workmanlike finishand are to be clean and free from such surface and internaldefects as can be established by the specified tests.

1.3.2 All pipes and tubes are to be reasonably straight.The ends are to be cut nominally square with the axis of thepipe or tube, and are to be free from excessive burrs.


1.4.1 The tolerances on the wall thickness and diameterof pipes and tubes are to be in accordance with an accept-able National specification.


1.5.1 The requirements for the chemical composition ofladle samples and acceptable methods of deoxidation aredetailed in subsequent Sections in this Chapter.

1.6 Heat treatment

1.6.1 All pipes and tubes are to be supplied in the condition detailed in the relevant specific requirements.


Chapter 6Section 1


Steel Pipes and Tubes

1.7 Test material

1.7.1 Pipes and tubes are to be presented for test inbatches. The size of a batch and the number of tests to beperformed are dependent on the application.

1.7.2 Where heat treatment has been carried out, a batchis to consist of pipes or tubes of the same size, manufacturedfrom the same types of steel and subjected to the same finishing treatment in a continuous furnace, or heat treatedtogether in the same batch type furnace.

1.7.3 Where no heat treatment has been carried out, abatch is to consist of pipes or tubes of the same size manufactured by the same method from material of the sametype of steel.

1.7.4 For pipes for Class I pressure systems and boilerand superheater tubes, at least two per cent of the numberof lengths in each batch is to be selected at random for thepreparation of tests at ambient temperature.

1.7.5 For pipes for Class II pressure systems, each batchis to contain not more than the number of lengths given inTable 6.1.1. Tests are to be carried out on at least one pipeselected at random from each batch or part thereof.

1.8 Dimensions of test specimens and testprocedures

1.8.1 The procedures for mechanical tests and thedimensions of the test specimens are to be in accordancewith Chapter 2.

1.9 Visual and non-destructive testing

1.9.1 All pipes for Class I and II pressure systems, boilerand superheater tubes, are to be presented for visual examination and verification of dimensions. The manufactureris to provide adequate lighting conditions to enable an internaland external examination of the pipes and tubes to be carriedout.

1.9.2 For welded pipes and tubes, the manufacturer is toemploy suitable non-destructive methods for the qualitycontrol of the welds. It is preferred that this examination iscarried out on a continuous basis.

1.10 Hydraulic test

1.10.1 Each pipe and tube is to be subjected to ahydraulic test at the manufacturer’s works.

1.10.2 The hydraulic test pressure is to be determinedfrom the following formula, except that the maximum testpressure need not exceed 140 bar (143 kgf/cm2):

P = P = ( )where

P = test pressure, in bar (kgf/cm2)D = nominal outside diameter, in mmt = nominal wall thickness, in mms = 80 per cent of the specified minimum yield stress, in

N/mm2 (kgf/mm2), for ferritic steels and 70 per centof the specified minimum, 1,0 per cent proof stress,in N/mm2 (kgf/mm2), for austenitic steels. Theserelate to the values specified for acceptance testingat ambient temperature.

1.10.3 The test pressure is to be maintained for sufficienttime to permit proof and inspection. Unless otherwise agreed,the manufacturer’s certificate of satisfactory hydraulic test willbe accepted. Where it is proposed to adopt a test pressureother than that determined as in 1.10.2, the proposal will besubject to special consideration.

1.10.4 Subject to special approval, either an ultrasonic oreddy current test can be accepted in lieu of the hydraulic test.


1.11.1 Surface imperfections may be removed by grindingprovided that the thickness of the pipe or tube after dressingis not less than the required minimum thickness. The dressedarea is to be blended into the contour of the tube.

1.11.2 By agreement with the Surveyor, the repair of minordefects by welding can be accepted, subject to weldingprocedure tests which demonstrate acceptable propertiesappropriate for the grade of pipe to be repaired. Weld procedure tests are to be subjected to the same heat treatment as will be applied to the actual pipes after weldrepair.

1.11.3 The repaired area is to be tested by magnetic particle examination, or, for austenitic steels, by liquid penetrant examination on completion of welding, heat treatment and surface grinding.

1.12 Identification

1.12.1 Pipes and tubes are to be clearly marked by themanufacturer in accordance with the requirements ofChapter 1. The following details are to be shown on all materials which have been accepted:(a) LR or Lloyd’s Register.(b) Manufacturer’s name or trade mark.(c) Identification mark for the specification or grade of steel.(d) Identification number and/or initials which will enable the

full history of the item to be traced.(e) The personal stamp of the Surveyor responsible for the

final inspection.

200stD

20stD


Steel Pipes and Tubes Chapter 6Section 1

LLOYD’S REGISTER2

Outside diameter mm Number in batch

≤323,9 200 pipes as made

>323,9 100 pipes as made

Table 6.1.1 Batch sizes for pipes for Class II pressure systems

1.12.2 It is recommended that hard stamping be restrictedto the end face, but it may be accepted in other positions inaccordance with National Standards and practices.


1.13.1 Unless a LR certificate is specified in other parts ofthe Rules, a manufacturer’s certificate validated by LR is to beissued, see Ch 1,3.1.

1.13.2 The manufacturer is to provide LR with the following information:(a) Purchaser’s name and order number.(b) If known, the contract number for which the material is

intended.(c) Address to which material is despatched.(d) Specification or the grade of material.(e) Description and dimensions.(f) Identification number and/or initials.(g) Cast number and chemical composition of ladle

samples.(h) Mechanical test results, and results of the intercrystalline

corrosion tests where applicable.(j) Condition of supply.

1.13.3 As a minimum, the chemical composition stated onthe certificate is to include the content of all the elementsdetailed in the specific requirements. Where rimming steel issupplied, this is to be stated on the certificate.

1.13.4 When steel is not produced at the pipe or tube mill,a certificate is to be supplied by the steelmaker stating theprocess of manufacture, the cast number and the ladle analysis.

1.13.5 The steel manufacturer’s works is to be approvedby LR.

■ Section 2Seamless pressure pipes

2.1 Scope

2.1.1 Provision is made in this Section for seamless pressure pipes in carbon, carbon-manganese and low alloy steels.

2.1.2 Where pipes are used for the manufacture of pressure vessel shells and headers, the requirements for forgings in Ch 5,7 are applicable where the wall thicknessexceeds 40 mm.


2.2.1 Pipes are to be manufactured by a seamlessprocess and may be hot or cold finished.

2.2.2 The method of deoxidation and the chemicalcomposition of ladle samples are to comply with the appropriate requirements given in Table 6.2.1.





Che

mic

al c

ompo

sitio

n of

ladl

e sa

mpl

es %

Met

hod

ofTy

pe o

f ste

elG

rade

deox

idat

ion

CS

iM

nS

PR

esid

ual e

lem

ents

max

.m

ax.

320

Sem

i-kille

d≤0

,16

–0,

40—

0,70

0,05

00,

050

Ni

0,30

max

.36

0or

kille

d≤0

,17

≤0,3

50,

40—

0,80

0,04

50,

045

Cr

0,25

max

.C

arbo

n an

dca

rbon

-41

0≤0

,21

≤0,3

50,

40—

1,20

0,04

50,

045

Mo

0,10

max

.

man

gane

seC

u0,

30 m

ax.

460

Kille

d≤0

,22

≤0,3

50,

80—

1,40

0,04

50,

045

Tota

l0,

70 m

ax.

490

≤0,2

3≤0

,35

0,80

—1,

500,

045

0,04

5

Ni

Cr

Mo

Cu

Sn

VA

l

1Cr1

/ 2M

o44

0K

illed

0,10

—0,

180,

10—

0,35

0,40

—0,

700,

040

0,04

00,

300,

70–1

,10

0,45

— 0

,65

0,25

0,03

—≤0

,020

max

.m

ax.

max

.

21/ 4

Cr1

Mo

410

Kille

d0,

08—

0,15

0,10

—0,

500,

40—

0,70

0,04

00,

040

0,30

2,0—

2,5

0,90

—1,

200,

250,

03—

≤0,0

2049

0m

ax.

max

.m

ax.

1 /2C

r1/ 2

Mo1

/ 4V

460

Kille

d0,

10—

0,18

0,10

—0,

350,

40—

0,70

0,04

00,

040

0,30

0,30

—0,

600,

50—

0,70

0,25

0,03

0,22

—0,

32≤0

,020

max

.m

ax.

Tab

le 6

.2.1

Che

mic

al c

om

po

siti

on

of

seam

less

pre

ssur

e p

ipes

2.3 Heat treatment

2.3.1 Pipes are to be supplied in the condition given inTable 6.2.3.


2.4.1 All pipes are to be presented in batches as definedin Section 1.

2.4.2 Each pressure pipe selected for test is to besubjected to tensile and flattening or bend tests.

2.4.3 The results of all mechanical tests are to complywith the appropriate requirements given in Table 6.2.2.

2.5 Mechanical properties for design

2.5.1 Values for nominal minimum lower yield or 0,2 percent proof stress at temperatures of 50°C and higher aregiven in Table 6.2.4 and are intended for design purposesonly. Verification of these values is not required, except formaterials complying with National or proprietary specificationwhere the elevated temperature properties used for designare higher than those given in Table 6.2.4.

2.5.2 In such cases, at least one tensile test at theproposed design or other agreed temperature is to be madeon each cast. The test specimen is to be taken from materialadjacent to that used for tests at ambient temperature andtested in accordance with the procedures given in Chapter 2.If tubes or pipes of more than one thickness are supplied fromone cast, the test is to be made on the thickest tube or pipe.

2.5.3 As an alternative to 2.5.2, a manufacturer may carryout an agreed comprehensive test program for a stated gradeof steel to demonstrate that the specified minimum mechanical properties at elevated temperatures can beconsistently obtained. This test program is to be carried outunder the supervision of the Surveyors, and the resultssubmitted for assessment and approval. When a manufac-turer is approved on this basis, tensile tests at elevatedtemperatures are not required for acceptance purposes, butat the discretion of the Surveyors occasional check tests ofthis type may be requested.


Elongation Flattening Bend testType of steel Grade

Yield stress Tensile strengthon 5,65 So test constant diameter of former

N/mm2 N/mm2% minimum C (t = thickness)

320 195 320—440 25 0,10360 215 360—480 24 0,10

Carbon and 410 235 410—530 22 0,08 4tcarbon-manganese 460 265 460—580 21 0,07

490 285 490—610 21 0,07

1Cr1/2Mo 440 275 440—590 22 0,07 4t

410 135 410—560 20(see Note 1) 0,07

21/4Cr1Mo 490 275 490—640 16 4t(see Note 2)

1/2Cr1/2Mo1/4V 460 275 460—610 15 0,07 4t

NOTES1. Annealed condition.2. Normalised and tempered condition.



LLOYD’S REGISTER4

Table 6.2.2 Mechanical properties for acceptance purposes: seamless pressure pipes (maximum wall thickness 40 mm), see 2.1.2

Type of steel Condition of supply

Carbon andcarbon-manganese

Hot finished Hot finished (see Note 1)Normalised (see Note 2)

Cold finished Normalised (see Note 2)

Alloy steel

1Cr1/2Mo Normalised and tempered

21/4Cr1Mo Grade 410 Fully annealedGrade 490 Normalised and tempered

650—780°CGrade 490 Normalised and tempered

650—750°C

1/2Cr1/2Mo1/4V Normalised and tempered

NOTES1. Provided that the finishing temperature is sufficiently high

to soften the material.2. Normalised and tempered at the option of the manufacturer.

Table 6.2.3 Heat treatment


Chapter 6Section 2




Type of steel Grade Temperature °C50 100 150 200 250 300 350 400 450 500 550 600

320 172 168 158 147 125 100 91 88 87 — — —Carbon and 360 192 187 176 165 145 122 111 109 107 — — —

carbon- 410 217 210 199 188 170 149 137 134 132 — — —manganese 460 241 234 223 212 195 177 162 159 156 — — —

490 256 249 237 226 210 193 177 174 171 — — —

1Cr1/2Mo 440 254 240 230 220 210 183 169 164 161 156 151 —

410 121 108 99 92 85 80 76 72 69 66 64 62(see Note 1)

21/2Cr1Mo490 268 261 253 245 236 230 224 218 205 189 167 145

(see Note 2)

1/2Cr1/2Mo1/4V 460 266 259 248 235 218 192 184 177 168 155 148 —


Table 6.2.4 Mechanical properties for design purposes: seamless pressure pipes

Carbon and carbon-manganese 1Cr1/2Mo 21/4Cr1Mo 1/2Cr1/2Mo1/4V

Grade Grade Grade Grade Grade Grade

Temperature 320 460 440 410 490 460

°C 360 490 Annealed Normalised and410 tempered

(see Note)

380 171 227 — — — —390 155 203 — — — —

400 141 179 — — — —410 127 157 — — — —420 114 136 — — — —430 102 117 — — — —440 90 100 — — — —

450 78 85 — 196 221 —460 67 73 — 182 204 —470 57 63 — 168 186 —480 47 55 210 154 170 218490 36 47 177 141 153 191

500 — 41 146 127 137 170510 — — 121 115 122 150520 — — 99 102 107 131530 — — 81 90 93 116540 — — 67 78 79 100

550 — — 54 69 69 85560 — — 43 59 59 72570 — — 35 51 51 59580 — — — 44 44 46

NOTEWhen the tempering temperature exceeds 750°C, the values for Grade 410 are to be used.

Table 6.2.5 Mechanical properties for design purposes: seamless pressure pipes – Estimated values for stressto rupture in 100 000 hours (units N/mm2)

■ Section 3Welded pressure pipes

3.1 Scope

3.1.1 Provision is made in this Section for welded pressure pipes in carbon, carbon-manganese and low alloysteels.


3.2.1 Pipes are to be manufactured by the electric resistance or induction welding process and, if required, maybe subsequently hot reduced or cold finished.

3.2.2 Where it is proposed to use other weldingprocesses, details of the welding processes and proceduresare to be submitted for review.

3.2.3 In all cases, welding procedure tests are required.Test samples are to be subjected to the same heat treatmentas the pipe.


3.3 Heat treatment

3.3.1 Pipes are to be supplied in the heat treated condition given in Table 6.3.3.


3.4.1 All pipes are to be presented in batches as definedin Section 1.

3.4.2 Each pressure pipe selected for test is to besubjected to tensile and flattening or bend tests.



3.5.1 The mechanical properties at elevated temperaturefor carbon and carbon-manganese steels in Grades 320 to460 and 1Cr1/2Mo steel can be taken from the appropriateTables in Section 2.



LLOYD’S REGISTER6

Che

mic

al c

ompo

sitio

n of

ladl

e sa

mpl

es %

Met

hod

ofTy

pe o

f ste

elG

rade

deox

idat

ion

CS

iM

nS

PR

esid

ual e

lem

ents

max

.m

ax.

320

Any

met

hod

≤0,1

6—

0,30

—0,

700,

050

0,05

0N

i0,

30 m

ax.

Car

bon

and

360

(see

Not

e)≤0

,17

≤0,3

50,

40—

1,00

0,04

50,

045

Cr

0,25

max

.

carb

on-

Mo

0,10

max

.

man

gane

se41

0≤0

,21

≤0,3

50,

40—

1,20

0,04

50,

045

Cu

0,30

max

.K

illed

460

≤0,2

2≤0

,35

0,80

—1,

400,

045

0,04

5To

tal

0,70

max

.

Ni

Cr

Mo

Cu

Sn

Al

1Cr1

/ 2M

o44

0K

illed

0,10

—0,

180,

10—

0,35

0,40

—0,

700,

040

0,04

00,

300,

70—

1,10

0,45

—0,

650,

250,

03≤0

,020

max

.m

ax.

max

.

NO

TEFo

r rim

min

g st

eels

, the

car

bon

cont

ent m

ay b

e in

crea

sed

to 0

,19%

max

.

Tab

le 6

.3.1

Che

mic

al c

om

po

siti

on

of

wel

ded

pre

ssur

e p

ipes


4.3 Heat treatment

4.3.1 Pipes are to be supplied in the condition given inTable 6.4.3.


4.4.1 All pipes are to be presented for test in batches asdefined in Section 1 for Class 1 pressure piping systems, butin addition the material in each batch is to be from the samecast.

4.4.2 At least two per cent of the number of lengths ineach batch is to be selected at random for the preparation oftests.

4.4.3 Each pressure pipe selected for test is to besubjected to tensile, flattening or bend test at room tempera-ture and, where the wall thickness is 6 mm or greater, animpact test at the test temperature specified in Table 6.4.2.

4.4.4 The impact tests are to consist of a set of threeCharpy V-notch test specimens cut in the longitudinal direction with the notch perpendicular to the original surfaceof the pipe. The dimensions of the test specimens are to be inaccordance with the requirements of Chapter 2.

4.4.5 The results of all tensile, flattening and bend testsare to comply with the appropriate values in Table 6.4.2.

4.4.6 The average value for impact test specimens is tocomply with the appropriate requirements of Table 6.4.2. Oneindividual value may be less than the required average valueprovided that it is not less than 70 per cent of this value. SeeCh 2,1.4.1 for re-test procedures.

■ Section 4Ferritic steel pressure pipes forlow temperature service

4.1 Scope

4.1.1 Provision is made in this Section for carbon,carbon-manganese and nickel pipes intended for use in thepiping arrangements for liquefied gases where the designtemperature is less than 0°C. These requirements are alsoapplicable for other types of pressure piping systems wherethe use of steels with guaranteed impact properties at lowtemperatures is required.


4.2.1 Carbon and carbon-manganese steel pipes are tobe manufactured by a seamless, electric resistance or induction welding process.

4.2.2 Nickel steel pipes are to be manufactured by aseamless process.

4.2.3 Seamless pipes may be hot finished or cold finished.Welded pipes may be as-welded, hot finished or cold finished.The terms ‘hot finished’, ‘cold finished’ and ‘as-welded’ applyto the condition of the pipes before final heat treatment.





Tensile Elongation FlatteningType of steel Grade

Yield stressstrength on 5,65 So test constantN/mm2N/mm2 % minimum C

320 195 320 – 440 25 0,10Carbon and 360 215 360 – 480 24 0,10carbon-manganese 410 235 410 – 530 22 0,08

460 265 460 – 580 21 0,07

1Cr1/2Mo 440 275 440 – 590 22 0,07

Table 6.3.2 Mechanical properties for acceptance purposes: welded pressure pipes


Carbon and carbon- Normalisedmanganese, see Note (Normalised and tempered at

the option of the manufacturer)

1Cr1/2Mo Normalised and tempered

NOTESubject to special approval, electric resistance welded (ERW)pipes and tubes in grades 320 and 360 may be supplied withoutheat treatment for the following applications:(a) Class 2 piping systems, except for liquefied gases or other

low temperature applications.(b) Class 3 piping systems.

Table 6.3.3 Heat treatment: welded pressure pipes

Chemical composition of ladle sample %Type of

GradeMethod of

steel deoxidation C Si Mn P S Ni Alsol Residualmax. max. max. see Note elements

Carbon 360 0,17 0,10—0,35 0,40—1,00 0,030 0,025 — 0,015 min. Cr 0,25Cu 0,30Mo 0,10

Carbon- 410 and 0,20 0,10—0,35 0,60—1,40 0,030 0,025 — 0,015 min. Ni 0,30manganese 460 Fully

killed Total 0,70

31/2Ni 440 0,15 0,15—0,35 0,30—0,90 0,025 0,020 3,25—3,75 — Cr 0,25Cu 0,30Mo 0,10

9Ni 690 0,13 0,15—0,30 0,30—0,90 0,025 0,020 8,50—9,50 — Total 0,60

NOTEWhere a minimum Alsol of 0,015% is specified, the determination of the total aluminium is acceptable provided that the result is not lessthan 0,020%.



LLOYD’S REGISTER8


Charpy V-notch

Yield Tensile Elongation Flattening Bend test impact tests

Type of steel Grade stress strength on 5,65 Sotest diameter of former

N/mm2 N/mm2 % minimum constant (t = thickness)Test Average

Ctemperature energy

°C J minimum

Carbon 360 210 360—480 24 0,10 4t –40 27

Carbon- 410 235 410—530 22 0,08 4t –50 27manganese 460 260 460—580 21 0,07

31/2Ni 440 245 440—590 16 0,08 4t –95 34

9Ni 690 510 690—840 15 0,08 4t –196 41


Subsidiary SubsidiaryRequired average energy 10 mm x 7,5 mm 10 mm x 5 mm

value for standard10 mm x 10 mm Average Average

energy energy

27 J 22 J 18 J34 J 28 J 23 J41 J 34 J 27 J

For standard subsidiary impact test specimens, the minimum energyvalues are to be as follows:


Carbon and Hot finishedcarbon-manganese Normalised


31/2 Ni NormalisedNormalised and tempered

9Ni Double normalised and temperedQuenched and tempered

Table 6.4.3 Heat treatment

■ Section 5Austenitic stainless steel pressurepipes

5.1 Scope

5.1.1 Provision is made in this Section for austenitic stainless steel pipes suitable for use in the construction of thepiping systems for chemicals and for liquefied gases wherethe design temperature is not less than minus 165°C and forbulk chemical tankers.

5.1.2 Austenitic stainless steels are also suitable forservice at elevated temperatures. Where such applications areproposed, details of the chemical composition, heat treatmentand mechanical properties are to be submitted for consider-ation and approval.

5.1.3 Where it is intended to supply seamless pipes in thedirect quenched condition, a programme of tests for approvalis to be carried out under the supervision of the Surveyors,and the results are to be to the satisfaction of LR, seeCh 1,2.2.


5.2.1 Pipes are to be manufactured by a seamless or acontinuous automatic electric fusion welding process.

5.2.2 Welding is to be in a longitudinal direction, with orwithout the addition of filler metal.

5.2.3 The chemical composition of the ladle samples isto comply with the appropriate requirements of Table 6.5.1.

5.3 Heat treatment

5.3.1 Pipes are generally to be supplied by the manufac-turer in the solution treated condition over their full length.

5.3.2 Alternatively, seamless pipes may be direct quenchedimmediately after hot forming, while the temperature of thepipes is not less than the specified minimum solution treat-ment temperature.


5.4.1 All pipes are to be presented in batches as definedin Section 1 for Class I and II piping systems.

5.4.2 Each pipe selected for test is to be subjected totensile and flattening or bend tests.



Chapter 6Section 5



Chemical composition of ladle sample %

Type of steel Grade CSi Mn

P SCr Mo Ni Others

max. max. max.

304L 490 0,03 <1,00 <2,00 0,045 0,030 17,0 – 19,0 — 9,0 – 13,0 —

316L 490 0,03 <1,00 <2,00 0,045 0,030 16,0 – 18,5 2,0–3,0 11,0 – 14,5 —

Ti321 510 0,08 <1,00 <2,00 0,045 0,030 17,0 – 19,0 — 9,0 – 13,0 ≥5 x C

≤0,80

Nb347 510 0,08 <1,00 <2,00 0,045 0,030 17,0 – 19,0 — 9,0 – 13,0 ≥10 x C

≤1,00


0,2% proof1,0% proof Tensile Elongation Flattening Bend test

Type of steel Gradestress

stress strength on 5,65 So test constant diameter of formerN/mm2

N/mm2 N/mm2 % minimum C (t = thickness)(see Note)

304L 490 175 205 490 – 690 30 0,09 3t

316L 490 185 215 490 – 690 30 0,09 3t

321 510 195 235 510 – 710 30 0,09 3t

347 510 205 245 510 – 710 30 0,09 3t

NOTEThe 0,2% proof stress values given for information purposes and unless otherwise agreed are not required to be verified by test.


5.5 Intergranular corrosion tests

5.5.1 For materials used for piping systems for chemicals, intercrystalline corrosion tests are to be carried outon one per cent of the number of pipes in each batch, with aminimum of one pipe.

5.5.2 For pipes with an outside diameter not exceeding40 mm, the test specimens are to consist of a full cross-section. For larger pipes, the test specimens are to be cut ascircumferential strips of full wall thickness and having a widthof not less than 12,5 mm. In both cases, the total surface areais to be between 15 and 35 cm2.

5.5.3 Unless otherwise agreed or required for a particularchemical cargo, the testing procedure is to be in accordancewith Ch 2,9.

5.5.4 After immersion, the full cross-section test specimensare to be subjected to a flattening test in accordance with therequirements of Chapter 2. The strip test specimens are to besubjected to a bend test through 90° over a mandrel of diameter equal to twice the thickness of the test specimen.

5.6 Fabricated pipework

5.6.1 Fabricated pipework is to be produced from material manufactured in accordance with 5.2, 5.3, 5.4 and5.5.

5.6.2 Welding is to be carried out in accordance with anapproved and qualified procedure by suitably qualifiedwelders.

5.6.3 Fabricated pipework may be supplied in the as-welded condition without subsequent solution treatmentprovided that welding procedure tests have demonstratedsatisfactory material properties including resistance to intercrystalline corrosion.

5.6.4 In addition, butt welds are to be subjected to 5 percent radiographic examination for Class I, and 2 per cent forClass II pipes.

5.6.5 Fabricated pipework in the as-welded conditionand intended for systems located on deck is to be protectedby a suitable corrosion control coating.


5.7.1 Each test certificate is to be of the type and givethe information detailed in Ch 1,3.1 together with generaldetails of heat treatment and, where applicable, the resultsobtained from intercrystalline corrosion tests. As a minimum,the chemical composition is to include the content of all theelements detailed in Table 6.5.1.

■ Section 6Boiler and superheater tubes

6.1 Scope

6.1.1 Provision is made in this Section for boiler and super-heater tubes in carbon, carbon-manganese and low alloysteels.

6.1.2 Austenitic stainless steels may also be used for thistype of service. Where such applications are proposed, detailsof the chemical composition, heat treatment and mechanicalproperties are to be submitted for consideration and approval.


6.2.1 Tubes are to be seamless or welded and are to bemanufactured in accordance with the requirements of Sections 2 and 3, respectively.

6.2.2 The method of deoxidation and the chemicalcomposition of ladle samples are to comply with the require-ments given in Table 6.2.1 or 6.3.1, as appropriate.

6.3 Heat treatment

6.3.1 All tubes are to be supplied in accordance with therequirements given in Table 6.2.3 or 6.3.3 as appropriate,except that 1Cr1/2Mo steel may be supplied in the normalisedonly condition when the carbon content does not exceed 0,15 per cent.


6.4.1 Tubes are to be presented for test in batches asdefined in Section 1.

6.4.2 Each boiler and superheater tube selected for testis to be subjected to at least the following:(a) Tensile test.(b) Flattening or bending test.(c) Expanding or flanging test.



6.5.1 The mechanical properties at elevated temperaturefor carbon and carbon-manganese steels in Grades 320 to460, 1Cr1/2 Mo and 21/4Cr1Mo steels can be taken from theappropriate Tables in Section 2.

6.5.2 Where rimming steel is used, the design tempera-ture is limited to 400°C.


Steel Pipes and Tubes Chapter 6Sections 5 & 6


Drift expanding andflanging test

minimum % increase inYield Tensile Elongation Flattening Bend test

outside diameterType of steel Grade stress strength on 5,65 So test constant diameter of former

N/mm2 N/mm2 % minimum C (t = thickness) Inside diameterRatio

Outside diameter

≤0,6 >0,6 ≤0,8 >0,8

Carbon and320 195 320–440 25 0,10 12 15 19

carbon-360 215 360–480 24 0,10 12 15 19

manganese410 235 410–530 22 0,08 4t 10 12 17460 265 460–580 21 0,07 8 10 15

1Cr1/2Mo 440 275 440–590 22 0,07 4t 8 10 15

410 135 410–560 20(see Note 1) 0,07 4t 8 10 15

21/2Cr1Mo490 275 490–640 16

(see Note 2)



Chapter 6Section 6



Table 6.6.1 Mechanical properties for acceptance purposes: boiler and superheater tubes

Section


2 Grey iron castings

3 Spheroidal or nodular graphite iron castings

4 Compacted or vermicular graphite iron castings

5 Iron castings for crankshafts


1.1 Scope

1.1.1 This Section gives the general requirements for grey(flake), spheroidal (nodular) graphite and compacted (vermic-ular) graphite iron castings intended for use in the constructionof ships, other marine structures, machinery, boilers, pressurevessels and piping systems.

1.1.2 Where required by the relevant Rules dealing withdesign and construction, castings are to be manufacturedand tested in accordance with Chapters 1 and 2, togetherwith the requirements given in this Section and either Section 2 for grey iron castings, Section 3 for spheroidalgraphite iron castings or Section 4 for compacted graphite ironcastings. Castings for crankshafts are additionally to complywith the requirements detailed in Section 5.

1.1.3 As an alternative to 1.1.2, castings which complywith National or proprietary specifications may be accepted,provided that these specifications give reasonable equivalence to the requirements of this Chapter or alterna-tively are approved for a specific application. Generally, surveyand certification are to be carried out in accordance with therequirements of Chapter 1.

1.1.4 Where small castings are produced in large quantities, or where castings of the same type are produced inregular quantities, alternative survey procedures, in accordancewith Ch 1,2.2, may be adopted subject to approval by Lloyd’sRegister (hereinafter referred to as ‘LR’).

1.2 Manufacture

1.2.1 Castings as designated in 1.1.2 are to be made atfoundries approved by LR.

1.2.2 Suitable mechanical methods are to be employedfor the removal of surplus material from castings. Thermalcutting processes are not acceptable, except as a preliminaryoperation to mechanical methods.


1.3.1 Castings are to be free from surface or internaldefects which would be prejudicial to their proper applicationin service. The surface finish is to be in accordance with goodpractice and any specific requirements of the approved plan.


1.4.1 The chemical composition of the iron used is left tothe discretion of the manufacturer, who is to ensure that it issuitable to obtain the mechanical properties specified for thecastings.

1.5 Heat treatment

1.5.1 Except as required by 1.5.2, castings may besupplied in either the as cast or heat treated condition.

1.5.2 For some applications, such as elevated tempera-ture service, or where dimensional stability is important,castings may require to be given a suitable tempering orstress relieving heat treatment. This is to be carried out afterany refining heat treatment and before machining.

1.5.3 Where it is proposed to carry out local hardening ofthe surface of a casting, full details of the proposed procedureare to be submitted for approval.

1.6 Test material

1.6.1 At least one test sample is to be provided for eachcasting or batch of castings. For large castings, where morethan one ladle of metal is used, one test sample is to beprovided, from each ladle used.

1.6.2 A batch testing procedure may be adopted forcastings with a fettled mass of 1 tonne or less. All castings ina batch are to be of similar type and dimensions, and castfrom the same ladle of metal. One test sample is to beprovided for each multiple of two tonnes of fettled castings inthe batch.

1.6.3 Where separately cast test samples are used, theyare to be cast in moulds made from the same type of materialas used for the castings and are not to be stripped from themoulds until the temperature is below 500°C.

1.6.4 All test samples are to be suitably marked to identify them with the castings which they represent.

1.6.5 Where castings are supplied in the heat treatedcondition, the test samples are to be heat treated togetherwith the castings which they represent. For cast-on testsamples, the sample is not to be separated from the castinguntil after heat treatment.


Chapter 7Section 1


Iron Castings


1.7.1 One tensile specimen is to be prepared from eachtest sample. The dimensions of the test specimens and thetesting procedures used are to be in accordance withChapter 2.

1.7.2 The results of all tensile tests are to comply with therequirements given in Section 2, 3, 4 or 5, as appropriate.

1.7.3 In the case of castings supplied in the as castcondition which initially do not meet the requirements of 1.7.2,the manufacturer, by agreement with the purchaser, has theright to heat treat the castings, together with the representativetest samples, and re-submit them for acceptance.

1.7.4 In the case of a batch of castings supplied in theheat treated condition which initially do not meet the require-ments of 1.7.2, the manufacturer has the right to re-heat treatthe batch together with the representative test samples, andre-submit the castings for acceptance. The number of reheattreatments and retestings will be restricted to two.


1.8.1 All castings are to be cleaned and adequatelyprepared for examination. The surfaces are not to behammered, peened or treated in any way which may obscuredefects.

1.8.2 The accuracy and verification of dimensions are theresponsibility of the manufacturer, unless otherwise agreed.

1.8.3 All castings are to be presented to the Surveyor forvisual examination and this is to include the examination ofinternal surfaces where applicable.

1.8.4 The non-destructive examination of castings is notrequired unless otherwise stated in the approved plan orwhere there is reason to suspect the soundness of the casting.

1.8.5 In the event of any casting proving defective during subsequent machining or testing it is to be rejected notwithstanding any previous certification.


1.9.1 At the discretion of the Surveyor, small surfaceblemishes may be removed by local grinding.

1.9.2 Subject to the prior approval of the Surveyor, castings containing local porosity may be rectified by vacuumimpregnation with a suitable plastic filler, provided that theextent of the porosity is such that it does not adversely affectthe strength of the casting.

1.9.3 Repairs by welding are not permitted on grey castiron castings or compacted graphite iron castings and generallynot permitted for spheroidal or nodular graphite iron castings,but may be considered in special circumstances forspheroidal or nodular graphite iron castings. In such cases,full details of the proposed repair procedure are to be submit-ted for approval prior to the commencement of the proposedrectification.


1.10.1 When required by the relevant Rules, castings areto be pressure tested before final acceptance. These tests areto be carried out in the presence and to the satisfaction of theSurveyor.

1.11 Identification of castings

1.11.1 The manufacturer is to adopt a system of identifica-tion which will enable all finished castings to be traced to the original cast, and the Surveyor is to be given full facilities fortracing the castings when required.

1.11.2 Before acceptance, all castings which have beentested and inspected with satisfactory results are to be clearlymarked by the manufacturer with the following particulars:(a) Type and grade of cast iron.(b) Identification number, cast number or other marking

which will enable the full history of the casting to betraced.

(c) Manufacturer’s name or trade mark.(d) LR or Lloyd’s Register and the abbreviated name of LR’s

local office.(e) Personal stamp of Surveyor responsible for inspection.(f) Test pressure, where applicable.(g) Date of final inspection.




1.12.2 The manufacturer is to provide the Surveyor with awritten statement giving the following particulars for eachcasting or batch of castings which has been accepted:(a) Purchaser’s name and order number.(b) Description of castings and quality of cast iron.(c) Identification number.(d) General details of heat treatment, where applicable.(e) Results of mechanical tests.(f) Test pressure, where applicable.(g) When specially required, the chemical analysis of ladle

samples.


Iron Castings Chapter 7Section 1

LLOYD’S REGISTER2

1.12.3 Where applicable, the manufacturer is to provide asigned statement regarding non-destructive testing asrequired by 1.8, together with a statement and/or a sketchdetailing the extent and position of all weld repairs made toeach casting as required by 1.9.

■ Section 2Grey iron castings

2.1 Scope

2.1.1 This Section gives the specific requirements forgrey cast iron castings.

2.2 Test material

2.2.1 Separately cast test samples in the form of cylindrical bars, 30 mm diameter and of a suitable length, areto be used unless otherwise agreed by LR. Test samples ofother dimensions may be specially required for some components as may cast-on samples. In these circumstances,the tensile strength requirements are to be agreed.

2.2.2 When two or more test samples are cast simultaneously in a single mould, the bars are to be at least 50 mm apart.

2.2.3 Test samples may be cast integrally when a castingis both more than 20 mm thick and its mass exceeds 200 kg,subject to agreement between the manufacturer and thepurchaser. The type and location of the samples are to besuch as to provide approximately the same cooling conditionsas for the casting it represents and are also subject to agreement.

2.2.4 For continuous melting of the same grade of castiron in large tonnages the mass of a batch may be taken asthe output of two hours of pouring.

2.2.5 Where 2.2.4 applies and production is carefullymonitored by systematic checking of the melting process by,for example, chill testing, chemical analysis or thermal analysis, test samples may be taken at longer intervals asagreed by the Surveyor.


2.3.1 Only the tensile strength is to be determined, andthe results obtained from tests are to comply with the minimum value specified for the castings being supplied.Except for crankshaft castings (see Section 5), the specifiedtensile strength is to be not less than 200 N/mm2 subject toany additional requirements of the relevant Rules. The fractured surfaces of all tensile test specimens are to be granular and entirely grey in appearance.

■ Section 3Spheroidal or nodular graphiteiron castings

3.1 Scope

3.1.1 This Section gives the specific requirements forspheroidal or nodular graphite iron castings.

3.1.2 These requirements are generally applicable to castings intended for use at ambient temperatures. Additionalrequirements will be necessary when the castings areintended for service at either low or elevated temperatures.Impact test requirements are given for low temperatureservice in 3.4.2.

3.2 Heat treatment

3.2.1 The special qualities with 350 N/mm2 and 400 N/mm2 nominal tensile strength and impact test are toundergo a ferritising heat treatment, see 3.4.2.

3.3 Test material

3.3.1 The test samples are to be as detailed in Figs. 7.3.1, 7.3.2 or 7.3.3 The dimensions of the test specimens and testing procedures used are to be in accordance with Chapter 2. Test samples of other dimensionsmay be specially required for some castings and these are tobe agreed with the Surveyor.

3.3.2 The test samples may be either gated to the casting or separately cast.

3.3.3 Where separately cast test samples are used, theyare to be taken towards the end of pouring of the castings.


3.4.1 The tensile strength and elongation are to be determined and are to comply with the requirements ofTable 7.3.1. Minimum values for the 0,2 per cent proof stressare also included in this Table but are to be determined only ifincluded in the specification. Typical ranges of hardnessvalues are also given in Table 7.3.1 and are intended for information purposes.

3.4.2 Impact tests may be required for some applicationsin which case the selection of the grade is to be confined tothose listed in Table 7.3.2. These castings are to be given aferritising heat treatment. The mechanical test results are tocomply with Table 7.3.2.

3.4.3 Castings may be supplied to any specifiedminimum tensile strength selected within the general limitsdetailed in Tables 7.3.1 and 7.3.2 but subject to anyadditional requirements of the relevant Rules.


Chapter 7Sections 1, 2 & 3


Iron Castings

3.5 Metallographic examination

3.5.1 Samples for metallographic examination are to beprepared for spheroidal or nodular graphite iron castings.These samples are to be representative of each ladle usedand may conveniently be taken from the tensile test specimens. Alternative arrangements for the provision ofthese samples may, however, be adopted subject to theconcurrence of the Surveyor. They are, however, to be takentowards the end of the pour.

3.5.2 Examination of the samples is to show that at least90 per cent of the graphite is in a dispersed spheroidal ornodular form. Details of typical matrix structures are given inTable 7.3.1 and are intended for information purposes.


Iron Castings Chapter 7Section 3

LLOYD’S REGISTER4

Dimension Standard sample,mm

u 25v 90x 40y 100

Z To suit testing machineRs Approximately 5

z

y

xRs

u u u

v

3° taper

Fig. 7.3.2 Type B (Double U-type) test samples

Dimension Standard sample, Alternative samples when specially required,mm mm

u 25 12 50 75v 55 40 90 125x 40 30 60 65y 100 80 150 165

Z To suit testing machineRs Approximately 5

zv

u

x

y

Rs

3° taper

Fig. 7.3.1 Type A (U-type) test samples


Chapter 7Section 3


Iron Castings

Specified minimum0,2% proof stress

Elongation Typical hardness Typical structuretensile strength

(see Note)on 5,65 So value HB of matrix

N/mm2 N/mm2% minimum (see 3.4.1) (see 3.5.2)

minimum

370 230 17 120 – 180 Ferrite400 250 12 140 – 200 Ferrite500 320 7 170 – 240 Ferrite/pearlite600 370 3 190 – 270 Pearlite/ferrite700 420 2 230 – 300 Pearlite800 480 2 250 – 350 Pearlite or tempered structure

NOTEProof stresses need only be determined if specifically requested.

Table 7.3.1 Mechanical properties for acceptance purposes: spheroidal or nodular graphite iron castings

Dimension Standard sample, Alternative samples when specially required,mm mm

u 25 12 50 75v 55 40 100 125x 40 25 50 65y 140 135 150 175

Z To suit testing machine

Minimum thickness of mould surrounding 40 40 80 80

test sample

Fig. 7.3.3 Type C (Y-type) test samples

z

y

x

u

v

■ Section 4Compacted or vermicular graphiteiron castings

4.1 Scope

4.1.1 This Section gives the specific requirements forcompacted or vermicular graphite iron castings.

4.1.2 These requirements are generally applicable tocastings intended for use at ambient temperatures.

4.2 Heat treatment

4.2.1 Where castings do not meet the specified mechanicalproperty requirements in the as-cast condition, a correctiveheat treatment may be carried out. This is to be restricted toa single heat treatment and the test coupons must be heattreated with the castings.

4.3 Test material

4.3.1 The test samples are to be as detailed in Figs.7.3.1, 7.3.2 or 7.3.3. The dimensions of the test specimensand testing procedures used are to be in accordance withChapter 2. Test samples of other dimensions may be speciallyagreed with the Surveyor.

4.3.2 The test samples may be either gated to the castingor separately cast.


4.4.1 The tensile strength and elongation are to be deter-mined and are to comply with the requirements of Table 7.4.1.Minimum values for the 0,2 per cent proof stress are alsoincluded in this Table but are to be determined only if includedin the specification. Typical ranges of hardness values are alsogiven in Table 7.4.1 and are intended for informationpurposes.

4.4.2 Castings may be supplied to any specified minimumtensile strength grade.


Iron Castings Chapter 7Sections 3 & 4

LLOYD’S REGISTER6

17 (14)12 (10)

14 (11)12 (10)

Elongation

on 5,65 Sominimum

%(see Note 2)

Specified minimumtensile strength

N/mm2

0,2% proof stressminimum

(see Note 1) N/mm2

Typical hardnessvalue

Charpy V-notch impact tests

Test temperature °C(see Note 3)

Average energyJ minimum(see Note 4)

350

400

220

250

22

18

110 – 170

140 – 200

20–40

20–20

NOTES1. Proof stresses need only be determined if specifically requested.2. In the case of integrally cast samples, the acceptable elongation may be taken as 2 percentage points less.3. Tests need only be made at either of the temperatures listed, as appropriate.4. The average value measured on three Charpy V-notch specimens. One of the three values may be below the specified minimum average

value, but not less than the value shown in brackets.5. Typical structure of the matrix is ferrite.

Table 7.3.2 Mechanical properties: special qualities

Specified minimum0,2% proof stress

Elongation Typical hardness Typical structuretensile strength

(see Note)on 5,65 So value HB of matrix

N/mm2 N/mm2% minimum (see 4.4.1) (see 4.5.2)

minimum

300 210 2 140 – 210 Ferrite350 245 1,5 160 – 220 Ferrite/pearlite400 280 1 180 – 240 Pearlite/ferrite450 315 1 200 – 250 Pearlite500 350 0,5 220 – 260 Fully pearlitic

NOTEProof stresses need only be determined if specifically requested.

Table 7.4.1 Mechanical properties for acceptance purposes: compacted or vermicular graphite iron castings

4.5 Metallographic examination

4.5.1 Samples for metallographic examination are to beprepared for compacted or vermicular graphite iron castings.These samples are to be representative of each ladle usedand may conveniently be taken from the tensile test speci-mens. Alternative arrangements for the provision of thesesamples may, however, be adopted subject to the concur-rence of the Surveyor. They are, however, to be taken towardsthe end of the pour.

4.5.2 Examination of the samples is to show that at least80 per cent of the graphite is in a dispersed, compacted orvermicular form. The remaining 20 per cent of the graphitemay be in spheroidal forms. Details of typical matrix structuresare given in Table 7.4.1 and are intended for informationpurposes.

■ Section 5Iron castings for crankshafts

5.1 Scope

5.1.1 This Section gives additional requirements for castiron crankshafts intended for diesel engines and compressors.For both of these applications, details of the proposed specification are to be submitted for approval.

5.1.2 Crankshaft castings in grey iron and compactedgraphite iron are acceptable only for compressors, and thespecified minimum tensile strength is to be not less than 300N/mm2.

5.1.3 For crankshaft castings in spheroidal or nodulargraphite iron, the specified minimum tensile strength is to benot less than 370 N/mm2.

5.2 Manufacture

5.2.1 Details of the method of manufacture, including thearrangements proposed for the provision of test material, areto be submitted for approval.

5.2.2 Tests to demonstrate the soundness of prototypecastings and the mechanical properties at important locationswill be required.

5.3 Heat treatment

5.3.1 In general, crankshaft castings other than thosewhich are fully annealed, normalised or oil quenched andtempered, are to receive a suitable stress relief heat treatmentbefore machining.

5.3.2 Where it is proposed to harden the surfaces ofmachined pins and/or journals of cast iron crankshafts, detailsof the process are to be submitted for approval. Before sucha process is applied to a crankshaft it is to be demonstratedby procedure tests, and to the satisfaction of the Surveyor,that the process is suitably controlled and does not impair thestrength or soundness of the material.

5.4 Test material

5.4.1 Unless otherwise approved, the dimensions of thetest samples are to be such as to ensure that they havemechanical properties representative of those of the averagesection of the crankshaft casting.

5.4.2 For large crankshaft castings, the test samples areto be cast integral with, or gated from, each casting.

5.4.3 The batch testing procedure detailed in 1.6.2 maybe adopted only where small and identical crankshaft castings are produced in quantity. Generally, the fettled massof each casting in a batch is not to exceed 100 kg, and inaddition to tensile tests, the hardness of each casting is to be determined. For this purpose, a small flat is to be ground oneach crankshaft, and Brinell hardness tests are to be carriedout. The results obtained from these tests are to comply withthe approved specification.


5.5.1 Cast crankshafts are to be subjected to a fullmagnetic particle or dye penetrant examination after finalmachining and completion of any surface hardening opera-tions.

5.5.2 Particular attention is to be given to the testing ofthe pins, journals and associated fillet radii.

5.5.3 Cracks and crack-like defects are not acceptable.Fillet radii are to be free from any indications.


5.6.1 Cast iron crankshafts are not to be repaired by welding, and blemishes are not to be plugged with a filler.


5.7.1 The chemical composition of ladle samples is to begiven in addition to the other particulars detailed in 1.12.2.




Iron Castings

1.2.2 The alloys may be cast either in ingot moulds or byan approved continuous casting process. Plates are to beformed by rolling and may be hot or cold finished. Bars andsections may be formed by extrusion, rolling or drawing.

1.2.3 All melts are to be suitably degassed prior to castingsuch that the aim hydrogen content is less than 0,2 ml per 100 g.

1.3 Quality of materials

1.3.1 Materials are to be free from surface or internaldefects of such a nature as would be harmful in service.

1.3.2 The manufacturer is to verify the integrity of pressure welds of closed extrusion profiles in accordance with1.10.


1.4.1 Underthickness tolerances for rolled products formarine construction are given in Table 8.1.1.

1.4.2 Underthickness tolerances for extruded productsare to comply with an acceptable National or InternationalStandard.

1.4.3 There are to be no underthickness tolerances formaterials for application in cryogenic process pressurevessels.

1.4.4 Dimensional tolerances other than permitted underthicknesses are to comply with an acceptable Nationalor International Standard.

1.4.5 Verification of dimensions is the responsibility of themanufacturer. Acceptance by Surveyors of material which islater found to be defective does not absolve the manufacturerfrom this responsibility.

Section

1 Plates, bars and sections

2 Aluminium alloy rivets

3 Aluminium alloy castings

4 Aluminium/steel transition joints

■ Section 1Plates, bars and sections

1.1 Scope

1.1.1 This Section makes provision for aluminium alloyplates, bars and sections intended for use in the constructionof ships and other marine structures and for cryogenic applications.

1.1.2 Except as provided in 1.1.4, all items are to bemanufactured and tested in accordance with the appropriaterequirements of Chapters 1 and 2 and those detailed in thisSection.

1.1.3 The thickness of plates, sections and barsdescribed by these requirements will be in the range between3 and 50 mm. Plates and sections less than 3,0 mm thickmay be manufactured and tested in accordance with therequirements of an acceptable national specification.

1.1.4 Plates less than 3,0 mm thick and sections lessthan 40 mm x 40 mm x 3,0 mm may be manufactured andtested in accordance with the requirements of an acceptableNational specification.

1.1.5 Where the section thickness exceeds 50 mm, therequirements will be subject to special consideration.

1.1.6 Materials intended for the construction of cargotanks or storage for liquefied gases, and for other low temperature applications, are to be manufactured in the 5083 alloy in the annealed condition.

1.1.7 As an alternative to 1.1.2 and 1.1.4, materialswhich comply with National or proprietary specifications maybe accepted provided that these specifications give reasonable equivalence to the requirements of this Sectionand are approved for a specific application. Generally, surveyand certification are to be carried out in accordance with therequirements of Chapter 1.

1.2 Manufacture

1.2.1 Aluminium alloys are to be manufactured at worksapproved by Lloyd’s Register (hereinafter referred to as ‘LR’).


Chapter 8Section 1


Aluminium Alloys

Table 8.1.1 Underthickness tolerances for rolledproducts for marine construction

≥3,0 <4,0

≥4,0 <8,0

≥8,0 <12

≥12 <20

≥20 <50

≤1500

0,10

0,20

0,25

0,35

0,45

>1500 ≤2000

0,15

0,20

0,25

0,40

0,50

>2000 ≤3500

0,15

0,25

0,25

0,50

0,65

Underthickness tolerance for nominal width range,mm

Nominal thickness

range,mm


1.5.1 Samples for chemical analysis are to be takenrepresentative of each cast, or the equivalent where a continuous melting process is involved.

1.5.2 The chemical composition of these samples is tocomply with the requirements of Table 8.1.2.

1.6 Heat treatment

1.6.1 The Aluminium 5000 series alloys, capable of beingstrain hardened, are to be supplied in any of the followingtemper conditions:

O annealedH111 annealed with slight strain hardeningH112 strain hardened from working at elevated

temperaturesH116 strain hardened and with specified resistance

to exfoliation corrosion for alloys where themagnesium content is 4 per cent or more

H321 strain hardened and stabilised.

1.6.2 The H116 temper is specially developed for use ina marine environment.

1.6.3 The Aluminium 6000 series alloys, capable of beingage hardened, are to be supplied in either of the followingtemper conditions:

T5 hot worked and artificially agedT6 solution treated and artificially aged.

1.7 Test material

1.7.1 Materials of the same product form, (i.e., plates,sections or bars) and thickness and from a single cast orequivalent, are to be presented for test in batches of not morethan 2 tonnes, with the exceptions of those given in 1.7.2,1.7.3 and 1.7.4.

1.7.2 For single plates or coils weighing more than 2 tonnes, only one tensile specimen per plate or coil is to betaken.

1.7.3 A tensile test specimen is required from each plateto be used in the construction of cargo tanks, secondary barriers and process pressure vessels with design temperatures below –55°C.

1.7.4 Extrusions, bars and sections of less than 1 kg/m innominal weight are to be tested in batches of 1 tonne. Wherethe nominal weight is greater than 5 kg/m, one tensile test isto be carried out for every three tonnes produced, or fractionsthereof.

1.7.5 If the material is supplied in the heat treated condition, each batch is to be treated together in the samefurnace or subjected to the same finishing treatment when acontinuous furnace is used.

1.7.6 For plates over 300 mm in width, tensile test specimens are to be cut with their length transverse to theprincipal direction of rolling. For narrow plates and for sectionsand bars, the test specimens are to be cut in the longitudinaldirection. Longitudinal tensile test specimens are accepted forthe strain hardenable 5000 series alloys.


Aluminium Alloys Chapter 8Section 1

LLOYD’S REGISTER2

Table 8.1.2 Chemical composition, percentage

Element

Copper

Magnesium

Silicon

Iron

Manganese

Zinc

Chromium

Titanium

Zirconium

Other elements:each

total

NOTES1. These alloys are not normally acceptable for application in direct contact with sea-water.2. Mn + Cr = 0,10 min., 0,60 max.3. Mn + Cr = 0,12 min., 0,50 max.

5083

0,10 max.

4,0—4,9

0,40 max.

0,40 max.

0,40—1,00

0,25 max.

0,05—0,25

0,15 max.

0,05 max.

0,15 max.

5383

0,20 max.

4,0—5,2

0,25 max.

0,25 max.

0,7—1,0

0,40 max.

0,25 max

0,15 max.

0,20 max.

0,05 max.

0,15 max.

5059

0,25 max.

5,0—6,0

0,45 max.

0,50 max.

0,6—1,2

0,40—0,90

0,25 max.

0,20 max.

0,05—0,25

0,05 max.

0,15 max.

5086

0,10 max.

3,5—4,5

0,40 max.

0,50 max.

0,20—0,70

0,25 max.

0,05—0,25

0,15 max.

0,05 max.

0,15 max.

5754

0,10 max.

2,6—3,6

0,40 max.

0,40 max.

0,50 max.(see Note 2)

0,20 max.


0,15 max.

0,05 max.

0,15 max.

5456

0,10 max.

4,7—5,5

0,25 max.

0,40 max.

0,50—1,00

0,25 max.

0,05—0,20

0,20 max.

0,05 max.

0,15 max.

6005–A(see Note 1)

0,30 max.

0,40—0,70

0,50—0,90

0,35 max.


0,20 max.


0,10 max.

0,05 max.

0,15 max.

6061(see Note 1)

0,15—0,40

0,80—1,20

0,40—0,80

0,70 max.

0,15 max.

0,25 max.

0,04—0,35

0,15 max.

0,05 max.

0,15 max.

6082

0,10 max.

0,60—1,20

0,70—1,30

0,50 max.

0,40—1,00

0,20 max.

0,25 max.

0,10 max.

0,05 max.

0,15 max.


Chapter 8Section 1


Aluminium Alloys

Alloy and temper Thickness, t, 0,2% proof stress Tensile strength

Elongation Elongation on condition, see Note 3 mm

Rp, Rm 4d, % 5,65 So 5d,%N/mm2 N/mm2

5083-O 3 ≤ t ≤ 50 (see Note 2) 125 275–350 16 14

5083-H111 3 ≤ t ≤ 50 125 275–350 16 14

5083-H112 3 ≤ t ≤ 50 125 275 12 10

5083-H116 3 ≤ t ≤ 50 215 305 10 10

5083-H321 3 ≤ t ≤ 50 215–295 305–380 12 10

5086-O 3 ≤ t ≤ 50 100 240–305 16 14

5086-H111 3 ≤ t ≤ 50 100 240–305 16 14

5086-H112 3 ≤ t ≤12,5 125 250 8 —12,5 < t ≤ 50 105 240 — 9

5086-H116 3 ≤ t ≤ 50 195 275 10 (see Note 1) 9

5059-O 3 ≤ t ≤ 50 160 330 24 24

5059-H111 3 ≤ t ≤ 50 160 330 24 24

5059-H116 3 ≤ t ≤ 20 270 370 10 1020 < t ≤ 50 260 360 10 10

5059-H321 3 ≤ t ≤ 20 270 370 10 1020 < t ≤ 50 260 360 10 10

5383-O 3 ≤ t ≤ 50 145 290 17 17

5383-H111 3 ≤ t ≤ 50 145 290 17 17

5754-H111 3 ≤ t ≤ 50 80 190–240 18 17

5383-H116 3 ≤ t ≤ 50 220 305 10 10

5383-H321 3 ≤ t ≤ 50 220 305 10 10

5456-O 3 ≤ t ≤ 6,3 130–205 290–365 16 —6,3 ≤ t ≤ 50 125–205 285–360 16 14

3 ≤ t ≤ 30 230 315 10 105456-H116 30 < t ≤ 40 215 305 — 10

40 < t ≤ 50 200 285 — 10

3 ≤ t ≤ 12,5 230–315 315–405 12 —5456-H321 12,5 ≤ t ≤ 40 215–305 305–385 — 10

40 ≤ t ≤ 50 200–295 285–370 — 10

5754-O 3 ≤ t ≤ 50 80 190–240 18 17

NOTES1. 8% for thickness up to and including 6,3 mm.2. For application to liquefied natural gas carriers or liquefied natural gas tankers where thicknesses are in excess of 50 mm, the mechanical

properties given in this table are, in general, to be complied with.3. The mechanical properties for the O and H111 tempers are the same for all alloys shown in this Table. However, they are separated in this

Table as they are made using different manufacturing processes.

Table 8.1.3 Minimum mechanical properties for acceptance purposes of selected rolled aluminium alloyproducts

1.7.7 Longitudinal tensile test specimens from a plate areto be taken at 1/3 width from the longitudinal edge.Longitudinal tensile test specimens taken from extrudedsections should be taken in the range from 1/3 to 1/2 of thedistance from the edge to the centre of the thickest region ofthe section.


1.8.1 At least one tensile test specimen is to be preparedfrom each batch of material submitted for acceptance.

1.8.2 Tensile test specimens are to be machined to thedimensions given in Fig. 2.2.3 in Chapter 2. Alternatively,machined proportional test specimens of circular cross-section in accordance with Fig. 2.2.2 in Chapter 2 may beused provided that the diameter is not less than 10 mm.Round bars may be tested in full section, or test specimensmay be machined in accordance with the dimensions givenin Fig. 2.2.2 in Chapter 2.

1.8.3 The results of all tensile tests are to comply with thevalues given in Tables 8.1.3 and 8.1.4, as applicable.

1.9 Corrosion tests

1.9.1 Rolled 5000 series alloys of type 5083, 5383, 5059,5456 and 5086 in the H116 and H321 tempers intended foruse in marine hull construction or in marine applications withfrequent direct contact with seawater are to be corrosiontested with respect to exfoliation and intergranular corrosionresistance.

1.9.2 The manufacturer is to establish the relationshipbetween microstructure and resistance to corrosion when theabove alloys are approved. A reference photomicrographtaken at 500x under the conditions specified in ASTM B928Section 9.4.1, is to be prepared for each of the alloy-tempersand thickness ranges relevant. The reference photographsare to be taken from samples which have exhibited noevidence of exfoliation corrosion and a pitting rating of PB orbetter, when subjected to the test described in ASTM G66(ASSET).The samples are also to have exhibited resistance to



LLOYD’S REGISTER4

Table 8.1.4 Minimum mechanical properties for acceptance purposes of selected extruded aluminium alloyproducts

Alloy and temper Thickness, t, 0,2% proof stress Tensile strength

Elongation Elongation on condition, see Note 2 mm

Rp, Rm 4d, % 5,65 So 5d,%N/mm2 N/mm2

5083-O 3 ≤ t ≤ 50 110 270–350 14 12

5083-H111 3 ≤ t ≤ 50 165 275 12 10

5083-H112 3 ≤ t ≤ 50 110 270 12 10

5086-O 3 ≤ t ≤ 50 95 240–315 14 12

5086-H111 3 ≤ t ≤ 50 145 250 12 10

5086-H112 3 ≤ t ≤ 50 95 240 12 10

5059-H112 3 ≤ t ≤ 50 200 330 10 10

5383-O 3 ≤ t ≤ 50 145 290 17 17

5383-H111 3 ≤ t ≤ 50 145 290 17 17

5383-H112 3 ≤ t ≤ 50 190 310 13 13

6005A-T5 3 ≤ t ≤ 50 215 260 9 8

6005A-T6 3 ≤ t ≤ 10 215 260 8 610 < t ≤ 50 200 250 8 6

6061-T6 3 ≤ t ≤ 50 240 260 10 8

6082-T5 3 ≤ t ≤ 50 230 270 8 6

6082-T6 3 ≤ t ≤ 5 250 290 6 —5 < t ≤ 50 260 310 10 8

NOTES1. The values are applicable for longitudinal and transverse tensile test specimens as well.2. The mechanical properties for the O and H111 tempers are the same for all alloys shown in this Table. However, they are separated in this

Table as they are made using different manufacturing processes.


Chapter 8Section 1


Aluminium Alloys

intergranular corrosion at a mass loss no greater than 15 mg/cm2, when subjected to the test described in ASTM G67 (NAMLT). Upon satisfactory establishment of therelationship between microstructure and resistance tocorrosion, the master photomicrographs and the results ofthe corrosion tests are to be approved by LR. Productionpractices are not to be changed after approval of thereference micrographs.

1.9.3 For batch acceptance of 5000 series alloys in theH116 and H321 tempers, metallographic examination of onesample selected from mid width at one end of a coil orrandom sheet or plate is to be carried out. The micro-structure of the sample is to be compared to the referencephotomicrograph of acceptable material in the presence ofthe Surveyor. A longitudinal section perpendicular to the rolledsurface is to be prepared for metallographic examination, underthe conditions specified in ASTM B928 Section 9.6.1. If themicrostructure shows evidence of continuous grain boundarynetwork of aluminium-magnesium precipitate in excess of thereference photomicrographs of acceptable material, thebatch is either to be rejected or tested for exfoliationcorrosion resistance and intergranular corrosion resistancesubject to the agreement of the Surveyor. The corrosion testsare to be in accordance with ASTM G66 and G67 orequivalent standards. Acceptance criteria are that the sampleshall exhibit no evidence of exfoliation corrosion and a pittingrating of PB or better when test subjected to ASTM G66(ASSET) test, and the sample is to exhibit resistance tointergranular corrosion at a mass loss no greater than 15 mg/cm2 when subjected to ASTM G67 (NAMLT) test. Ifthe results from testing satisfy the acceptance criteria statedin 1.9.2, the batch is accepted, otherwise it is to be rejected.

1.9.4 As an alternative to metallographic examination,each batch may be tested for exfoliation corrosion resistanceand intergranular corrosion resistance, in accordance withASTM G66 and G67 under the conditions specified in ASTMB298, or equivalent standards. If this alternative is used, thenthe results of the test must satisfy the acceptance criteriastated in 1.9.2.

1.9.5 Tempers that are corrosion tested in accordancewith 1.9.3 are to be marked ‘M’ after the temper condition,e.g., 5083 H321 M.

1.10 Pressure weld tests

1.10.1 The integrity of pressure welds of closed profileextrusions is to be verified by examination of macrosections ordrift expansion tests.

1.10.2 Every closed profile extrusion is to be sampled,except where the closed profile extrusions are equal to orshorter than 6,0 m long, in which case a batch is to comprisefive profiles. Every sample is to be tested at both ends afterfinal heat treatment.

1.10.3 Where verification is by examination of macro-sections, no indication of lack of fusion is permitted.

1.10.4 Where verification of fusion at pressure welds ofclosed profile extrusions is by drift expansion test, testing is tobe generally in accordance with Ch 2,4.3. The minimumincluded angle of the mandrel is to be 60°, and the minimumspecimen length, 50 mm. For acceptance, there is to be nofailure by a clean split along the weld line.


1.11.1 Surface inspection and verification of dimensionsare the responsibility of the manufacturer, and acceptance bythe Surveyors of material later found to be defective shall notabsolve the manufacturer from this responsibility.

1.11.2 In general, the non-destructive examination of materials is not required for acceptance purposes.Manufacturers are expected, however, to employ suitablemethods of non-destructive examination for the general maintenance of quality standards.

1.11.3 For applications where the non-destructive examination of materials is considered to be necessary, theextent of this examination, together with appropriate acceptance standards, are to be agreed between thepurchaser, manufacturer and Surveyor.


1.12.1 Slight surface imperfections may be removed bymechanical means, provided that the prior agreement of theSurveyor is obtained, that the work is carried out to his satisfaction and that the final dimensions are acceptable. Therepair of defects by welding is not allowed.

1.13 Identification

1.13.1 The manufacturer is to adopt a system of identification which will ensure that all finished material in abatch presented for test is of the same nominal chemical composition.

1.13.2 Products are to be clearly marked by the manufac-turer in accordance with the requirements of Chapter 1. Thefollowing details are to be shown on all materials which havebeen accepted:(a) Manufacturer’s name or trade mark.(b) Alloy grade and temper condition.(c) Identification mark which will enable the full history of the

item to be traced.(d) The stamp of the LR brand, .


1.14.1 A manufacturer’s certificate validated by LR is to beissued, see Ch 1,3.1.

2.3 Heat treatment

2.3.1 Rivets are to be supplied in the following condition:5154A – annealed6082 – solution treated.

2.4 Test material

2.4.1 Bars intended for the manufacture of rivets are tobe presented for test in batches of not more than 250 kg. Thematerial in each batch is to be the same diameter and nominal chemical composition.

2.4.2 At least one test sample is to be selected from eachbatch and, prior to testing, is to be heat treated in full cross-section and in a manner simulating the heat treatment appliedto the finished rivets.


2.5.1 At least one tensile and one dump test specimenare to be prepared from each test sample.

2.5.2 The tensile test specimen may be either a suitablelength of bar tested in full cross-section or a specimenmachined to the dimensions given in Fig. 2.2.2 in Chapter 2.

2.5.3 The dump test specimen is to consist of a sectioncut from the bar with the ends perpendicular to the axis. Thelength of this section is to be equal to the diameter of the bar.

2.5.4 The results of tensile tests are to comply with theappropriate requirements of Table 8.2.2.

2.5.5 The dump test is to be carried out at ambienttemperature and is to consist of compressing the specimenuntil the diameter is increased to 1,6 times the original diameter. After compression, the specimen is to be free fromcracks.

2.6 Tests from manufactured rivets

2.6.1 At least three samples are to be selected from eachconsignment of manufactured rivets. Dump tests as detailedin 2.5 are to be carried out on each sample.

1.14.2 Each test certificate is to include the followingparticulars:(a) Purchaser’s name and order number.(b) Contract number.(c) Address to which material is to be despatched.(d) Description and dimensions.(e) Alloy grade and temper condition.(f) Identification mark which will enable the full history of the

item to be traced.(g) Chemical composition.(h) Mechanical test results (not required on shipping

statement).(j) Details of temper condition and heat treatment, where

applicable.(k) Corrosion test results (as applicable).

1.14.3 Where the alloy is not produced at the works atwhich it is wrought, a certificate is to be supplied by themanufacturer of the alloy stating the cast number and chemical composition. The works at which the alloy wasproduced must be approved by LR.

■ Section 2Aluminium alloy rivets

2.1 Scope

2.1.1 Provision is made in this Section for aluminium alloyrivets intended for use in the construction of marine structures.

2.1.2 They are to be manufactured and tested in accordance with the appropriate requirements of Section 1and those detailed in this Section.


2.2.1 The chemical composition of bars used for themanufacture of rivets is to comply with the requirements ofTable 8.2.1.


Aluminium Alloys Chapter 8Sections 1 & 2

LLOYD’S REGISTER6

Mechanical properties 5154A 6082

0,2% proof stress N/mm2 min. 90 120

Tensile strength N/mm2 min. 220 190

Elongation on 5,65 So % min. 18 16

Table 8.2.2 Mechanical properties for acceptancepurposes

Element 5154A 6082

Copper 0,10 max. 0,10 max.Magnesium 3,1 – 3,9 0,6 – 1,2Silicon 0,50 max. 0,7 – 1,3Iron 0,50 max. 0,50 max.Manganese 0,1 – 0,5 0,4 – 1,0Zinc 0,20 max. 0,20 max.Chromium 0,25 max. 0,25 max.Titanium 0,20 max. 0,10 max.Other elements: each 0,05 max. 0,05 max.

total 0,15 max. 0,15 max.Aluminium Remainder Remainder



3.4.1 The chemical composition of a sample from eachcast is to comply with the requirements given in Table 8.3.1.Suitable grain refining elements may be used at the discretionof the manufacturer. The content of such elements is to bereported in the ladle analysis.

3.4.2 Where it is proposed to use alloys not specified inTable 8.3.1, details of the chemical composition, heat treatment and mechanical properties are to be submitted forapproval.

3.4.3 When a cast is wholly prepared from ingots forwhich an analysis is already available, and provided that nosignificant alloy additions are made during melting, the ingotmaker’s certified analysis can be accepted subject to occasional checks as required by the Surveyor.

3.5 Heat treatment

3.5.1 Castings are to be supplied in the following conditions:

Grade Al-Mg 3 – as-manufacturedGrade Al-Si 12 – as-manufacturedGrade Al-Si 10 Mg – as-manufactured or solution

heat treated and precipitationhardened

Grade Al-Si 7 Mg – solution heat treated and(high purity) – precipitation hardened.


3.6.1 At least one tensile specimen is to be tested fromeach cast and, where heat treatment is involved, for each heattreatment batch from each cast. Where continuous melting isemployed, 500 kg of fettled castings may be regarded as acast.




Aluminium Alloys

Alloy Al–Mg 3 Al–Si 12 Al–Si 10 Mg Al–Si 7Element High purity

Copper 0,1 max. 0,1 max. 0,1 max. 0,1 max.

Magnesium 2,5—4,5 0,1 max. 0,15—0,4 0,25—0,45

Silicon 0,5 max. 11,0—13,5 9,0—11,0 6,5—7,5

Iron 0,5 max. 0,7 max. 0,6 max. 0,2 max.

Manganese 0,6 max. 0,5 max. 0,6 max. 0,1 max.

Zinc 0,2 max. 0,1 max. 0,1 max. 0,1 max.

Chromium 0,1 max. — — —

Titanium 0,2 max. 0,2 max. 0,2 max. 0,2 max.

Others each 0,05 max. 0,05 max. 0,05 max. 0,05 max.

Total 0,15 max. 0,15 max. 0,15 max. 0,15 max.

Aluminium Remainder Remainder Remainder Remainder


2.7 Identification

2.7.1 Each package of manufactured rivets is to be identified with attached labels giving the following details:(a) Manufacturer’s name or trade mark.(b) Alloy grade.(c) Rivet size.


2.8.1 A manufacturer’s certificate is to be issued (see Ch 1,3.1) and for each consignment of manufacturedrivets is to include the following particulars:(a) Purchaser’s name and order number.(b) Description and dimensions.(c) Specification.

■ Section 3Aluminium alloy castings

3.1 Scope

3.1.1 Provision is made in this Section for aluminium alloycastings intended for use in the construction of ships, shipsfor liquid chemicals and other marine structures and liquefiedgas piping systems where the design temperature is not lowerthan minus 165°C. These materials should not be used forpiping systems outside cargo tanks except for short lengths ofpipes attached to the cargo tanks in which case fire-resistinginsulation should be provided.

3.1.2 Castings are to be manufactured and tested inaccordance with Chapters 1 and 2 and also with the requirements of this Section.

3.1.3 As an alternative to 3.1.2, castings which complywith National or proprietary specifications may be acceptedprovided that these specifications give reasonable equiva-lence to the requirements of this Section or are approved fora specific application. Generally, survey and certification areto be carried out in accordance with the requirements ofChapter 1.

3.2 Manufacture

3.2.1 Castings are to be manufactured at foundriesapproved by LR.


3.3.1 All castings are to be free from surface or internaldefects which would be prejudicial to their proper applicationin service.

3.7 Visual examination

3.7.1 All castings are to be cleaned and adequatelyprepared for inspection.

3.7.2 The accuracy and verification of dimensions are theresponsibility of the manufacturer, unless otherwise agreed.

3.7.3 Before acceptance, all castings are to be presentedto the Surveyor for visual examination.


3.8.1 At the discretion of the Surveyor, small surfaceblemishes may be removed by local grinding.

3.8.2 Where appropriate, repair by welding may beaccepted at the discretion of the Surveyor. Such repair is to bemade in accordance with an approved procedure.


3.9.1 Where required by the relevant Rules, castings areto be pressure tested before final acceptance. Unless otherwise agreed, these tests are to be carried out in the presence and to the satisfaction of the Surveyor.

3.10 Identification

3.10.1 The manufacturer is to adopt a system of identifica-tion which will enable all finished castings to be traced to the original cast and the Surveyor is to be given full facilities fortracing the casting when required.

3.10.2 All castings which have been tested and inspectedwith satisfactory results are to be clearly marked with thefollowing details:(a) Identification number, cast number or other markings

which will enable the full history of the casting to be traced.(b) LR or Lloyd’s Register and the abbreviated name of LR’s

local office.(c) Personal stamp of the Surveyor responsible for the

inspection.(d) Test pressure where applicable.(e) Date of final inspection.



3.11.1 A LR certificate is to be issued (see Ch 1,3.1) givingthe following particulars for each casting or batch of castingswhich have been accepted:(a) Purchaser’s name and order number.(b) Description of castings and alloy type.(c) Identification number.(d) Ingot or cast analysis.(e) General details of heat treatment, where applicable.(f) Results of mechanical tests.(g) Test pressure, where applicable.

3.6.2 The test samples are to be separately cast inmoulds made from the same type of material as used for thecastings. These moulds should conform to NationalStandards.

3.6.3 The method and procedures for the identification ofthe test specimens, and the castings they represent, are tobe agreed with the Surveyor. The identification marks are tobe maintained during the preparation of test specimens.

3.6.4 Where castings are supplied in the heat treatedcondition, the test samples are to be heat treated togetherwith the castings which they represent prior to testing.

3.6.5 The results of all tensile tests are to comply with theappropriate requirements given in Table 8.3.2 and/orTable 8.3.3.

3.6.6 Where the results of a test do not comply with therequirements, the re-test procedure detailed in Ch 2,1.4 is tobe applied. Where castings are to be used in the heat treatedcondition, the re-test sample must have been heat treatedtogether with the castings it represents.



LLOYD’S REGISTER8

AlloyTemper Tensile strength Elongation

(see Note) N/mm2 %

Al–Mg 3 M 150 5Al–Si 12 M 170 3Al–Si 10 Mg M 170 3Al–Si 10 Mg TF 240 1,5Al–Si 7 Mg TF 250 5

NOTEM refers to as cast condition.TF refers to solution heat treated and precipitation hardened

condition.

Table 8.3.3 Minimum mechanical properties foracceptance purposes of chill-castreference test piece

AlloyTemper Tensile strength Elongation

(see Note) N/mm2 %

Al–Mg 3 M 150 5Al–Si 12 M 150 3Al–Si 10 Mg M 150 2Al–Si 10 Mg TF 220 1Al–Si 7 Mg TF 230 5

NOTEM refers to as cast condition.TF refers to solution heat treated and precipitation hardened

condition.

Table 8.3.2 Minimum mechanical properties foracceptance purposes of sand-castand investment cast reference testpieces

4.4.3 The shear and tensile strengths of all the test specimens are to comply with the requirements of the manufacturing specification.


Chapter 8Section 4


Aluminium Alloys

Load p Load pTest piece

Jig Jig

t + (0,10 to 0,15)

Fig. 8.4.1 Specimen and procedure for shear tests

Ram

Bondzone

Testspecimen

Baseblock

Fig. 8.4.2 Ram tensile test

■ Section 4Aluminium/steel transition joints

4.1 Scope

4.1.1 Provision is made in this Section for explosionbonded composite aluminium/steel transition joints used forconnecting aluminium structures to steel plating.

4.1.2 Each individual application is to be separatelyapproved as required by the relevant Rules dealing withdesign and construction.

4.2 Manufacture

4.2.1 Transition joints are to be manufactured by anapproved producer in accordance with an approved specification which is to include the maximum temperatureallowable at the interface during welding.

4.2.2 The aluminium material is to comply with therequirements of Section 1 and the steel is to be of an appropriate grade complying with the requirements of Ch 3,2.

4.2.3 Alternative materials which comply with International,National or proprietary specifications may be acceptedprovided that they give reasonable equivalence to the require-ments of 4.2.2 or are approved for a specific application.

4.2.4 Intermediate layers between the aluminium andsteel may be used, in which case the material of any suchlayer is to be specified by the manufacturer and is to berecorded in the approval certificate. Any such intermediatelayer is then to be used in all production transition joints.


4.3.1 Each composite plate is to be subjected to 100 percent visual and ultrasonic examination in accordance with arelevant National Standard to determine the extent of anyunbonded areas. Unbonded areas are unacceptable and anysuch area plus 25 mm of surrounding sound material is to bediscarded.


4.4.1 Two shear test specimens and two tensile testspecimens are to be taken from each end of each compositeplate for tests to be made on the bond strength. One shearand one tensile test specimen from each end are to be testedat ambient temperature after heating to the maximum allowable interface temperature, see 4.2.1; the other twospecimens are to be tested without heat treatment.

4.4.2 Shear tests may be made on a specimen as shownin Fig. 8.4.1 or an appropriate equivalent. Tensile tests maybe made across the interface by welding extension pieces toeach surface or by the ram method shown in Fig. 8.4.2 or byan appropriate alternative method.

4.4.4 If either the shear or tensile strength of the bond isless than the specified minimum but not less than 70 per centof the specified minimum, two additional shear and two tensiletest specimens from each end of the composite plate are tobe tested and, in addition, bend tests as described in 4.4.6and Table 8.4.1 are to be made.

4.4.5 If either the shear or tensile strength of the bond isless than 70 per cent of the specified minimum the cause is to be investigated. After evaluation of the results of this investigation, LR will consider the extent of composite platewhich is to be rejected.

4.4.6 Bend tests, when required, are to be made underthe following conditions, as listed in Table 8.4.1:(a) The aluminium plate is in tension.(b) The steel plate is in tension.(c) A side bend is applied.

4.5 Identification

4.5.1 Each acceptable transition strip is to be clearlymarked with the following particulars:(a) LR or Lloyd’s Register and the abbreviated name of

LR’s local office.(b) Manufacturer’s name or trade mark.(c) Identification mark for the grade of aluminium.(d) Identification mark for the grade of steel.The particulars are to be stamped on the aluminium surface atone end of the strip.


4.6.1 A manufacturer’s certificate validated by LR is to beissued (see Ch 1,3.1) and as a minimum is to include thefollowing particulars:(a) Purchaser’s name and order number.(b) The contract number for which the material is intended,

if known.(c) Address to which the material is dispatched.(d) Description and dimensions of the material.(e) Specifications or grades of both the aluminium alloy and

the steel and any intermediate layer.(f) Cast numbers of the steel and aluminium plates.(g) Identification number of the composite plate.(h) Mechanical test results (not required on shipping

statement).




Type of testMinimum Diameter

bend, degrees of former

Aluminium in tension 90 3T

Steel in tension 90 3T

Side bend 90 6T

NOTET is the total thickness of the composite plate.

Table 8.4.1 Bend tests on explosion bondedaluminium/steel composites

Section

1 Castings for propellers

2 Castings for valves, liners and bushes

3 Tubes

■ Section 1Castings for propellers

1.1 Scope

1.1.1 This Section gives the requirements for copper alloycastings for one-piece propellers and separately cast bladesand bosses for fixed pitch and controllable pitch propellers(CPP). These include contra-rotating propellers and propulsorsfitted to podded drives and azimuth units.

1.1.2 These castings are to be manufactured and testedin accordance with the appropriate requirements of Chapters 1and 2 and the specific requirements of this Section.

1.1.3 As an alternative to 1.1.2, castings which complywith National or proprietary specifications may be acceptedprovided that these specifications give reasonable equiva-lence to the requirements of this Section or alternatively areapproved for a specific application.

1.1.4 The appropriate requirements of this Section mayalso be applied to the repair and inspection of propellerswhich have been damaged during service.

1.1.5 Generally, survey and certification are to be carriedout in accordance with the requirements of Chapter 1.

1.2 Manufacture

1.2.1 All castings are to be manufactured at foundriesapproved by Lloyd’s Register (hereinafter referred to as ‘LR’).

1.2.2 The pouring is to be carried out into dried mouldsusing degassed liquid metal. The pouring is to avoid turbulentflow. Special devices and/or procedures are to be used toprevent slag flowing into the mould.



1.3.2 The removal and repair of defects are dealt with in1.9 and 1.10.


1.4.1 The chemical compositions of samples from eachmelt are to comply with the manufacturing specificationapproved by LR and also with the overall limits given in Table 9.1.1. In addition to carrying out chemical analysis forthe elements given in the Table, it is expected that manufac-turers will ensure that any harmful residual elements are withinacceptable limits.

1.4.2 The use of alloys whose chemical compositions aredifferent from those detailed in Table 9.1.1 will be given specialconsideration by LR.

1.4.3 The manufacturer is to maintain records of allchemical analyses, which are to be made available to theSurveyor so that he can satisfy himself that the chemicalcomposition of each casting is within the specified limits.


Chapter 9Section 1


Copper Alloys

Table 9.1.1 Chemical composition of propeller and propeller blade castings

Chemical composition of ladle samples %Alloy designation

Cu Sn Zn Pb Ni Fe Al Mn

Grade Cu 1Manganese bronze 52–62 1,5 max. 35–40 0,5 max. 1,0 max. 0,5–2,5 0,5–3,0 0,5–4,0

(high tensile brass)

Grade Cu 2Ni-manganese bronze 50–57 0,1–1,5 33–38 0,5 max. 3,0–8,0 0,5–2,5 0,5–2,0 1,0–4,0


Grade Cu 3Ni-aluminium bronze 77–82 0,1 max. 1,0 max. 0,03 max. 3,0–6,0 2,0–6,0 7,0–11,0 0,5–4,0

(see Note) (see Note)

Grade Cu 4Mn–aluminium bronze 70–80 1,0 max. 6,0 max. 0,05 max. 1,5–3,0 2,0–5,0 6,5–9,0 8,0–20,0

NOTEFor Naval ships, the nickel content is to be higher than the iron content.


1.7.1 At least one tensile test specimen representative ofeach cast is to be prepared. The dimensions of this test specimen are to be in accordance with Fig. 2.2.1 in Chapter 2.

1.7.2 The results of all tensile tests are to comply with therequirements given in Table 9.1.2.

1.7.3 The mechanical properties of alloys whose chemical compositions do not accord with Table 9.1.1 are tocomply with a manufacturing specification approved by LR.

0,2% proof Tensilestress strength

Elongation

Alloy designation N/mm2 N/mm2 on 5,65 Soominimum minimum

% minimum

Grade Cu 1Manganese bronze 175 440 20


Grade Cu 2Ni-manganese bronze 175 440 20


Grade Cu 3Ni-aluminium bronze 245 590 16

Grade Cu 4Mn-aluminium bronze 275 630 18

Table 9.1.2 Mechanical properties for acceptancepurposes: propeller and propellerblade castings

1.4.4 When a melt is wholly prepared from ingots forwhich an analysis is already available, and provided that nosignificant alloy additions are made during melting, the ingotmaker’s certified analysis can be accepted subject to occasional checks as required by the Surveyor. If any foundryreturns are added to the melts, the ingot manufacturer’s chemical analyses are to be supplemented by frequentchecks as required by the Surveyor.

1.4.5 For alloys Grade Cu 1 and Cu 2, the zinc equiva-lent shall not exceed 45 per cent, and is to be calculatedusing the following formula:

zinc equivalent % = 100 –

where A is the algebraic sum of the following:1 x % Sn5 x % Al–0,5 x % Mn–0,1 x % Fe–2,3 x % Ni

1.4.6 Samples for metallographic examination are to beprepared from the ends of test bars cast from every melt ofGrade Cu 1 and Cu 2 alloys. The proportion of alpha-phase determined from the average of at least five counts is to benot less than 25 per cent.

1.5 Heat treatment

1.5.1 At the option of the manufacturer, castings may besupplied in the ‘as-cast’ or heat treated condition. However, ifheat treatment is to be applied, full details are to be includedin the manufacturing specification.

1.5.2 If any welds are made in the propeller casting,stress relief heat treatment is required in order to minimise the residual stresses. Requirements concerning such heat treatment are given in 1.10.

1.6 Test material

1.6.1 Test samples are to be cast separately from eachmelt used for the manufacture of propeller or propeller blade castings.

1.6.2 The test samples are to be of the keel block type,generally in accordance with the dimensions given in Fig. 9.1.1and are to be cast in moulds made from the same type ofmaterial as used for the castings.

1.6.3 The method and procedures for the identification ofthe test specimens, and the castings they represent, are tobe agreed with the Surveyor. The identification marks are tobe transferred and maintained during the preparation of testspecimens.

1.6.4 Where castings are supplied in the heat treatedcondition, the test samples are to be heat treated togetherwith the castings which they represent.

100 x %Cu100 + A


Copper Alloys Chapter 9Section 1

LLOYD’S REGISTER2

Approx. 50 mm

Approx. 150 mm

App

rox.

100

mm

Approx.15 mm

25 mm

Fig. 9.1.1 Keel block type test sample

1.8 Inspection and non-destructive examination

1.8.1 Propeller castings should be visually inspected atall stages of manufacture. The manufacturer is to draw anysignificant imperfections to the attention of the Surveyor. Suchimperfections are to be verified in accordance with 1.9.

1.8.2 All finished castings are to be subjected to acomprehensive visual examination by the Surveyor, includinginternal surfaces such as the bore and bolt holes. Whereunauthorised weld repairs are suspected by the Surveyor, thearea is to be etched (e.g., by iron chloride) for the purpose ofconfirmation.

1.8.3 For the purpose of these requirements, the bladesof propellers, including CPP blades, are divided into threeseverity Zones A, B and C as shown in Fig. 9.1.2 and detailedin 1.8.4 for blades having skew angles of 25° or less and 1.8.5for blades having skew angles of greater than 25°.

1.8.4 Skew angles of 25° or less:• Zone A is the area on the pressure side of the blade from

and including the root fillet to 0,4R and bounded by thetrailing edge and by a line at a distance 0,15 times thechord length from the leading edge.

• Zone B includes the areas inside 0,7R on both sides ofthe blade, excluding Zone A.

• Zone C includes the areas outside 0,7R on both sides ofthe blade.

1.8.5 Skew angles of greater than 25°:• Zone A is the area on the pressure side of the blade

bounded by, and including, the root fillet and a linerunning from the junction of the leading edge with theroot fillet to the trailing edge at 0,9R and passing throughthe mid-point of the chord at 0,7R and a point situated at0,3 of the chord length from the leading edge at 0,4R.

• Zone A also includes the area along the trailing edge onthe suction side of the blade from the root to 0,9R andwith its inner boundary at 0,15 of the chord length tapering to meet the trailing edge at 0,9R.

• Zone B constitutes the whole of the remainder of theblade surfaces.

1.8.6 In propeller blades with continuously loaded tips(CLT), the whole of the tip plate and the adjoining blade to adistance of 100 mm is to be regarded as severity Zone B, seeFig. 9.1.3. For propellers with diameters less than 2 m, thewidth of this zone may be reduced to one tenth of thepropeller radius.

1.8.7 In addition, the palm of a CPP blade is divided intoseverity Zones A and B as shown in Fig. 9.1.4.

1.8.8 If a CPP blade has an integrally cast journal, thefillets of the journal and the adjoining material up to a distanceof 20 mm from the fillet run-outs are to be regarded as Zone B,as indicated in Fig. 9.1.5. The remainder of the surface of thejournal may be regarded as Zone C.

1.8.9 Hubs of controllable pitch propellers are to containa Zone A region at each blade port as shown in Fig. 9.1.6.The remainder may be regarded as Zone C.


Chapter 9Section 1


Copper Alloys

4875/04

100 mm

Blade

Tip plate

Zone B (shaded)

Fig. 9.1.3Severity Zone B at Continuously loaded blade tip

R = propeller radiusCr = chord length at radius r

NOTEFor a definition of skew angle, see the relevant Rules

0,7R

0,4RFillet

Pressure side

C

B

A

0,15Cr

Leading edge

0,7R

C

B

Suction side

(a) Blades with propeller skew angles of 25° or less

Leading edge

Fillet

0,5Cr0,9R

0,7R

0,4R

0,3Cr

Pressure side

(b) Blades with propeller skew angles of greater than 25°

Suction side

0,15Cr

0,9RA ABB

r

Fig. 9.1.2 Severity zones in all propeller blades

1.8.10 On completion of machining and grinding, thewhole surface of each casting is to be subjected to a dyepenetrant inspection in accordance with a procedure accept-able to LR.



LLOYD’S REGISTER4

Zone B

Zone A(including

bore holes)

b

Zone B

Section b-b

Section a-a

Leadingedge

Trailingedge

a a

Zone B

Zone A(see Section b-b)

4875/03

b

Zone A End offillet

20 mm

The surfaces of blades are to be divided into severity zones in accordance with Fig. 9.1.2

Zone B

r + 20 mm

r + 20 mm

4875/01

The surfaces of the journal which are not shadedare to be regarded as severity Zone C

Fig. 9.1.5Severity zones in integrally cast CPP blade journals

d2

d1

1,2 x d2

Zone C

Zone A(inside and

outside)

4875/02

(d1 and d2 = diameters)

Fig. 9.1.6Severity zones for controllable pitch propeller hub

Fig. 9.1.4 Severity zones for controllable pitch propeller blades

1.8.18 Where it is suspected that a casting contains internal defects, radiographic and/or ultrasonic examinationmay be required by the Surveyor. The acceptance criteria areto be agreed between the manufacturer and LR in accordancewith a recognised standard. The standard ASTM E272-99(Severity Level 2) or equivalent is to be the radiographic accep-tance standard for copper alloy castings. Ultrasonic testing ofCu 1 and Cu 2 is not considered in these Rules. For Cu 3 andCu 4, ultrasonic inspection of defects may be possible and isto comply with the requirements for steel castings.

1.8.19 The measurement of dimensional accuracy is theresponsibility of the manufacturer but the report on dimensional inspection is to be presented to the Surveyor whomay require checks to be made and to witness such checks.

1.8.20 Static balancing is to be carried out on all propellersin accordance with the approved plan. Dynamic balancing isnecessary for propellers running above 500 rpm.


1.9.1 The rectification of defective propeller and propellerblade castings is to be carried out in accordance with therequirements given in 1.9.2 to 1.9.12.

1.9.2 The rectification of small indications within theacceptance standard of Table 9.1.3 is not generally requiredexcept where they occur in closely spaced groups.

1.8.11 All dye penetrant inspections on Zone A areas inthe finished condition are to be made in the presence of theSurveyor.

1.8.12 Dye penetrant inspections on Zones B and C are tobe performed by the manufacturer and may be witnessed atthe Surveyor’s request.

1.8.13 The surface to be inspected shall be divided intoreference areas of 100 cm2. The indications detected shall,with respect to their size and number, not exceed the valuesgiven in Table 9.1.3. The area shall be taken in the mostunfavourable location relative to the indication being evaluated.

1.8.14 Indications exceeding the acceptance standard inTable 9.1.3 shall be repaired in accordance with 1.9.

1.8.15 All defects requiring repair by welding in newpropeller castings are to be recorded on sketches showingtheir locations and dimensions. Copies of these sketches areto be presented to the Surveyor prior to repair.

1.8.16 Where repairs have been made either by grindingor welding, the repaired areas are to be subjected to dyepenetrant inspection in the presence of the Surveyor, regardless of their location.

1.8.17 Where no welds have to be made on a casting, themanufacturer is to provide the Surveyor with a statement thatthis is the case.


Chapter 9Section 1

Copper Alloys

Table 9.1.3 Allowable number and size of dye penetrant indications in a reference area of 100 cm2 (see Note 1)

A

B

C

7

14

20

Non-linearLinear

Aligned

Non-linearLinear

Aligned

Non-linearLinear

Aligned

522

1044

1466

433

666

866

Severity Zones Max. total number of indications

Type of indications (see Note 2)

Max. number of each type(see Notes 3 and 4)

Max. acceptable value for‘a’ or ‘l’ of indications

(mm) (see Note 2)

NOTES1. The reference area is defined as an area of 0,1 m2, which may be square or rectangular, with the major dimension not exceeding

250 mm. The area shall be taken in the most unfavourable location relative to the indication being evaluated.2. Non-linear, linear and aligned indications are defined as follows:

3. Only indications that have any dimension greater than 1,5 mm shall be considered relevant.4. Single non-linear indications less than 2 mm in Zone A and less than 3 mm in other zones may be disregarded.5. The total number of non-linear indications may be increased to the maximum total number, or part thereof, represented by the absence of

linear or aligned indications.


b

a

a < 3b

non-linear

b a

a ≥ 3blinear aligned

d

l

d ≤ 2 mm

1.10.4 Defects to be repaired by welding are to be removedcompletely by mechanical means (e.g. grinding, chipping ormilling). Removal of defects in accordance with the require-ments for Zone A is to be demonstrated by dye penetrantinspection in the presence of the Surveyor. The excavation is tobe prepared in a manner which will allow good fusion and isto be clean and dry.

1.10.5 Metal arc welding with the electrodes or filler wireused in the procedure tests is to be used for all types ofrepairs. Welds should preferably be made in the downhand(flat) position. Where necessary, suitable preheat is to beapplied before welding, and the preheat temperature is to bemaintained until welding is completed.

1.10.6 When flux coated electrodes are used they are tobe dried immediately before use, in accordance with themanufacturer’s instructions.

1.10.7 All slag, undercuts and other defects are to beremoved before the subsequent run is deposited.

1.9.3 Where, in the surface of the end face or bore of apropeller boss, local pores are present which do not themselvesadversely affect the strength of the casting, they may be filledwith a suitable plastic filler after the appropriate preparation ofthe defective area. The foundry is to maintain records anddetails of all castings which have been so rectified.

1.9.4 Where unacceptable defects are found in a casting, they are to be removed by mechanical means, andthe surfaces of the resulting depressions are subsequently tobe ground smooth. Complete elimination of the defects is tobe proved by adequate dye penetrant inspection.

1.9.5 Shallow grooves or depressions resulting from theremoval of defects may, at the discretion of the Surveyor, beaccepted provided that they will cause no appreciable reduc-tion in the strength of the castings and that they are suitablyblended by grinding.

1.9.6 Welded repairs are to be undertaken only whenthey are considered to be necessary and approved by theSurveyor. In general, welds having an area less than 5 cm2 areto be avoided.

1.9.7 All weld repairs are to be carried out in accordancewith qualified procedures by suitably qualified welders, andare to be completed to the satisfaction of the Surveyor.Records are to be made available to the Surveyor.

1.9.8 Welding is generally not permitted in Zone A andwill only be allowed after special consideration.

1.9.9 Prior approval by the Surveyor is required for anywelds in Zone B. Complete details of the repair procedure areto be submitted for each case.

1.9.10 Repair by welding is allowed in Zone C providedthat there is compliance with 1.9.6 and 1.9.7.

1.9.11 The maximum area of any single repair and themaximum total area of repair in any one zone or region aregiven in Table 9.1.4.

1.9.12 Where it is proposed to exceed the areas given inTable 9.1.4, the nature and extent of the repair work are to beapproved by the Surveyor before commencement of therepair.

1.10 Weld repair procedure

1.10.1 Welding is to be carried out under cover in positionsfree from draughts and adverse weather conditions.

1.10.2 The manufacturer is to submit a detailed weldingprocedure specification covering the weld preparation, weldingparameters, filler metal, preheating, post-weld heat treatmentand inspection procedures.

1.10.3 Before welding is started, Welding ProcedureQualification tests are to be carried out and witnessed by theSurveyor. Each welder is to be qualified to carry out theproposed welding using the same process, consumable andposition which are to be used for the repair.



LLOYD’S REGISTER6

Severity zone Maximum individual Maximum total areaor region area of repair of repairs

Zone A Weld repairs not generally permitted

Defects that are not deeper than (t/40) mm or2 mm, whichever is greater, below the

Zone B minimum local thickness are to be removed by grinding. Defects which are deeper than allowable for removal by grinding may be repaired by welding.

200 cm2 or 2% x S,whichever is thegreater in combined

60 cm2 or 0,6% x S Zones B and C butZone C whichever is the not more than

greater 100 cm2 or 0,8% x S,whichever is thegreater, in Zone Bon the pressure side

Other regions 17 cm2 or 1,5% area 50 cm2 or 5% x area(see Note) of the region which- of the region which-

ever is the greater ever is the greater

where t = minimum local thickness in mm

S = area of one side of a blade = 0,79

D = finished diameter of propellerB = developed area ratioN = number of blades

NOTEOther regions include:(a) the bore;(b) the forward and aft faces of the boss;(c) the outer surface of the boss to the start of the blade root

fillets;(d) the inner face of a CPP blade palm;(e) all surfaces of CPP nose cones;(f) the surfaces of integral journals to CPP blades other than the

fillets.

D2 BN

Table 9.1.4 Permissible rectification of newpropellers by welding

1.10.13 On completion, welds are to be ground smooth forvisual examination and dye penetrant inspection. Where apropeller or propeller blade is to be stress relief heat treated,a visual examination is to be made before heat treatment, andboth visual and dye penetrant examinations are to be madeafter the stress relief heat treatment. Irrespective of location,all weld repairs are to be assessed according to Zone A inTable 9.1.3.

1.10.14 The foundry is to maintain full records detailing theweld procedure, heat treatment and extent and location ondrawings of repairs made to each casting. These records areto be available for review by the Surveyor, and copies of individual records are to be supplied to the Surveyor on request.

1.10.15 LR reserves the right to restrict the amount of repairwork accepted from a manufacturer when it appears thatrepetitive defects are the result of improper foundry techniques or practices.

1.11 Identification

1.11.1 Castings are to be clearly marked by the manufac-turer in accordance with the requirements of Chapter 1. Thefollowing details are to be shown on all castings which havebeen accepted:(a) Identification mark which will enable the full history of the

item to be traced.(b) Alloy grade.(c) LR or Lloyd’s Register and the abbreviated name of LR

local office.(d) Personal stamp of Surveyor responsible for the final

inspection.(e) Date of final inspection.(f) Skew angle, if in excess of 25°. See Pt 5, Ch 7,1 of the

Rules for Ships for the definition of skew angle.


1.12.1 A LR certificate is to be issued for each propeller,see Ch 1,3.1.

1.12.2 The manufacturer is to provide the Surveyor withthe following particulars for each casting:(a) Purchaser’s name and order number.(b) Description of casting.(c) Alloy designation and/or trade name.(d) Identification number of casting.(e) Cast identification number if different from (d).(f) Details of heat treatment, where applicable.(g) Skew angle, if in excess of 25°. See the relevant Rules

for the definition of skew angle.(h) Final weight of casting.(j) Results of non-destructive tests and details of test

procedures.(k) Proportion of alpha-structure for Cu1 and Cu2 alloys.(l) Results of mechanical tests.(m) A sketch showing the location and extent of welding

repairs (if any).

1.10.8 With the exception given in 1.10.9, all weld repairs inareas of solid propellers exposed to sea-water, and all repairsto separately cast blades, are to be stress relief heat treated.

1.10.9 Stress relief heat treatment is not mandatory afterwelding Grade Cu 3 castings in Zone C unless a weldingconsumable susceptible to stress corrosion (e.g. complyingwith the composition range of Grade Cu 4) is used. All weldsin Zones A and B however, must be stress relieved by heattreatment, regardless of alloy.

1.10.10 Propeller and propeller blades are to be stressrelieved within the following temperature ranges:

alloy Grades Cu 1 and Cu 2 350°C to 550°Calloy Grade Cu 3 450°C to 500°Calloy Grade Cu 4 450°C to 600°C

Soaking times are to be in accordance with Table 9.1.5, andsubsequent cooling from the soaking temperature is to besuitably controlled to minimise residual stresses and is not toexceed 50°C per hour until the temperature is below 200°C.Care should be taken to avoid heating castings in the Grade Cu 3 alloy at temperatures between 300° and 400°Cfor prolonged periods.

1.10.11 Stress relief heat treatment is to be carried out,where possible, in furnaces having suitable atmosphere andtemperature control. Sufficient thermocouples are to beattached to the casting to measure the temperature at positions of extremes of thickness.

1.10.12 As an alternative to 1.10.11, local stress relief heattreatment may be accepted, provided that the Surveyor is satisfied that the technique will be effective and that adequateprecautions are taken to prevent the introduction of detrimentaltemperature gradients. Where local stress relief heat treatmentis approved, adequate temperature control is to be provided.The area of the propeller or blade adjacent to the repair is to besuitably monitored and insulated to ensure that the requiredtemperature is maintained and that temperature gradients aremoderate. Care should be taken to select the shape of an areato be heat treated which will minimise residual stresses.

Stress relieftemperature

°C

(see Notes)

350

400

450

500

550

600

Hours per25 mm ofthickness

5

11/21/41/4

—

Maximumrecommended

total timehours

15

5

2

11/2

—

Hours per25 mm ofthickness

—

—

5

11/21/4

Maximumrecommended

total timehours

—

—

15

5

2

1


Chapter 9Section 1

Copper Alloys

Table 9.1.5 Soaking times for stress relief heattreatment of copper alloy propellers

Alloy Grade Cu1 and Cu2 Alloy Grade Cu3 and Cu4

NOTES1. Treatment at 550°C is not applicable to alloy Grade Cu3.2. Treatment at 600°C is only applicable to alloy Grade Cu4.


2.4.2 With the exception given in 2.4.3, chemical analysisis required on each cast.

2.4.3 Where a cast is wholly prepared from ingots forwhich an analysis is already available, and provided that nosignificant alloy additions are made during melting, the ingotmaker’s certified analysis can be accepted subject to occasionalcheck tests as requested by the Surveyor. The frequency ofthese check tests should, as a minimum, be one in every tencasts. If one of these check analyses fails to comply with thespecification, checks are to be made on the previous andsubsequent melts. If one or both of these further analyses isunsatisfactory, chemical analysis is to be carried out on allfurther melts until the Surveyor is satisfied that a return canbe made to the use of occasional check tests.

2.5 Heat treatment

2.5.1 Where required by the specification, castings maybe supplied in either the ‘as-cast’ or heat treated condition.

2.5.2 Where castings are supplied in a heat treatedcondition, the test samples are to be heat treated with thecastings they represent prior to the preparation of the tensiletest specimens.

2.6 Test material

2.6.1 Test material sufficient for the tests specified in2.6.4 and for possible re-test purposes is to be provided foreach cast of material.

2.6.2 The test material is to be separately cast intomoulds made of the same material as that used for the castings they represent.

2.6.3 For the alloys listed in Table 9.2.1, sand cast testbars are generally to be in accordance with Fig. 9.2.1.

2.6.4 For the alloys listed in Table 9.2.2, keel block typetest samples are to be in accordance with Fig. 9.1.1.

■ Section 2Castings for valves, liners andbushes

2.1 Scope

2.1.1 This Section makes provision for copper alloy castings for valves, liners, bushes and other fittings intendedfor use in the construction of ships, other marine structures,machinery and pressure piping systems.

2.1.2 Castings are to be manufactured and tested inaccordance with Chapters 1 and 2, and also with the requirements given in this Section.

2.1.3 As an alternative to 2.1.2, castings which complywith National or proprietary specifications may be acceptedprovided that these specifications give reasonable equiva-lence to the requirements of this Section or alternatively areapproved for a specific application. Generally, survey andcertification are to be carried out in accordance with therequirements of Chapter 1.

2.2 Manufacture

2.2.1 Castings are to be manufactured at foundriesapproved by LR.




2.4.1 The chemical composition is to comply with therequirements of a National or International Standard and,where appropriate, with the limits for the principal elementsof the preferred alloys listed in Tables 9.2.1 and 9.2.2.



LLOYD’S REGISTER8

Table 9.2.1 Chemical compositions of long freezing range alloys: principal elements only

Chemical compositionAlloy type Designation

Typical

Cu Sn Zn Pb Ni Papplications

Phosphor bronze Cu Sn11P 87,0 – 89,5 10,0 – 11,5 0,05 max. 0,25 max. 0,10 max. 0,5 – 1,0 Liners, bushes,Cu Sn12 85,0 – 88,5 11,0 – 13,0 0,50 max. 0,7 max. 2,0 max. 0,60 max. valves and

fittings

Gunmetal Cu Sn10 Zn2 Remainder 9,5 – 10,5 1,75 – 2,75 1,5 max. 1,0 max. —Liners, valves and fittings

Cu Sn5 Zn5 Pb5 83,0 – 87,0 4,0 – 6,0 4,0 – 6,0 4,0 – 6,0 2,0 max. 0,10 max.

Leaded gunmetalCu Sn7 Zn2 Pb3 85,0 – 89,0 6,0 – 8,0 1,5 – 3,0 2,5 – 3,5 2,0 max. 0,10 max. Bushes, valvesCu Sn7 Zn4 Pb7 81,0 – 85,0 6,0 – 8,0 2,0 – 5,0 5,0 – 8,0 2,0 max. 0,10 max. and fittingsCu Sn6 Zn4 Pb2 86,0 – 90,0 5,5 – 6,5 3,0 – 5,0 1,0 – 2,0 1,0 max. 0,05 max.

Cu Sn10 Pb10 78,0 – 82,0 9,0 – 11,0 2,0 max. 8,0 – 11,0 2,0 max. 0,10 max.

Leaded bronzeCu Sn5 Pb9 80,0 – 87,0 4,0 – 6,0 2,0 max. 8,0 – 10,0 2,0 max. 0,10 max.

BushesCu Sn7 Pb15 74,0 – 80,0 6,0 – 8,0 2,0 max. 13,0 – 17,0 0,5 – 2,0 0,10 max.Cu Sn5 Pb20 70,0 – 78,0 4,0– 6,0 2,0 max. 18,0 – 23,0 0,5 – 2,5 0,10 max.

2.6.5 If it is proposed to use any other form of test bar,this is to be agreed in advance with the Surveyor.

2.6.6 As an alternative, for liners and bushes, the testmaterial may be taken from the ends of the castings.


2.7.1 A tensile test specimen is to be prepared from eachtest sample. The dimensions of the specimens are to complywith Fig. 2.2.1 or Fig. 2.2.2 in Chapter 2.

2.7.2 The results of all tests are to comply with the appro-priate requirements given in Tables 9.2.3 and 9.2.4.

Table 9.2.2 Chemical compositions of short freezing range alloys: principal elements only

Chemical compositionAlloy type Designation

Typical

Cu Ni Fe Mn Cr Nb Si Alapplications

Cu Ni30 Fe1 Mn1 64,5 min. 29,0–31,0 0,5–1,5 0,6–1,2 – – 0,1 max. – Flanges, Copper 30% Cu Ni30 Fe1 Mn1 Nb Si Remainder 29,0–31,0 0,5–1,5 0,6–1,2 – 0,5–1,0 0,3–0,7 – valvesnickel Cu Ni30 Cr2 Fe Mn Si Remainder 29,0–32,0 0,5–1,0 0,5–1,0 1,5–2,0 – 0,15–0,50 – and fittings

(see Note 1)

Copper 10% Cu Ni10 Fe1 Mn1 84,5 min. 9,0–11,0 1,0–1,8 1,0–1,5 – 1,0 max. 0,10 max. – Flanges, nickel valves

and fittings

Aluminium Cu Al10 Fe5 Ni5 76,0–83,0 4,0–6,0 4,0–5,5 3,0 max. – – 0,1 max. 8,5–10,5 Bushes,bronze (see (see valves

Note 2) Note 2) and fittingsCu Al11 Fe6 Ni6 72,0–78,0 4,0–7,5 4,0–7,0 2,5 max. – – 0,1 max. 10,0–12,0

(see (seeNote 2) Note 2)

NOTES1. Normally alloy Cu Ni30 Cr2 Fe Mn Si contains 0,1 to 0,25% titanium and 0,05 to 0,15% zirconium.2. For Naval ships, the nickel content is to be higher than the iron content.


Chapter 9Section 2


Copper Alloys

55 mm dia.

65 mm

70 mm

2 mm 30 mm 50 mm 95 mm

165 mm

25 mm rad.

25 mm rad.20 mm

dia.

25 mm dia.

10 mm

4888/04

Fig. 9.2.1 Sand cast test bars for long freezing range alloys

2.8 Inspection

2.8.1 All castings are to be cleaned and adequatelyprepared for inspection. Before acceptance, all castings are tobe presented to the Surveyor for visual examination. This is toinclude the examination of internal surfaces, where applicable.

2.8.2 For valves and other pressure components, dyepenetrant inspection is required and the Surveyor is towitness the tests. Unless otherwise agreed, the acceptancecriteria to be applied are to meet the requirements of Table 9.2.5, or equivalent.

2.8.3 The accuracy and verification of dimensions are theresponsibility of the manufacturer. However, the report ondimensional inspection is to be presented to the Surveyor whomay request to witness confirmatory measurements.




Table 9.2.3 Mechanical properties of long freezing range alloys for acceptance purposes

0,2% proof stressTensile strength Elongation on 5,65 SoN/mm2 minimum

N/mm2 minimum % minimumAlloy type Designation (See Note 1)

Sand Centrifugal Sand Centrifugal Sand Centrifugal

Cu Sn11 P 130 170 250 330 5 4Phosphor bronze Cu Sn12 140 150 260 280 7 5

Gunmetal Cu Sn10 Zn2 130 130 270 250 13 5

Leaded gunmetal Cu Sn5 Zn5 Pb5 90 110 200 250 13 13Cu Sn7 Zn2 Pb3 130 130 230 260 14 12Cu Sn7 Zn4 Pb7 120 120 230 260 15 12Cu Sn6 Zn4 Pb2 110 110 220 240 15 12

Cu Sn10 Pb10 80 110 180 220 8 6Leaded bronze Cu Sn5 Pb9 60 90 160 200 7 6

Cu Sn7 Pb15 80 90 170 200 8 7Cu Sn5 Pb20 70 80 150 170 5 6

NOTES1. The 0,2% proof stress values are given for information purposes only and, unless otherwise agreed, are not required to be verified by test.2. Castings may be supplied in the chill cast condition in which case the mechanical properties requirements are to be in accordance with a

specification agreed by LR.

Table 9.2.4 Mechanical properties of short freezing range alloys for acceptance purposes

0,2% proof stressTensile strength Elongation on 5,65 SoN/mm2 minimum

N/mm2 minimum % minimumAlloy type Designation (See Note 1)

Sand Centrifugal Sand Centrifugal Sand Centrifugal

Copper 30% Nickel Cu Ni30 Fe1 Mn1 120 120 340 340 18 18Cu Ni30 Fe1 Mn1 Nb Si 230 — 440 — 18 —Cu Ni30 Cr2 Fe Mn Si 250 — 440 — 18 —

Copper 10% Nickel Cu Ni10 Fe1 Mn1 120 100 280 280 20 25

Aluminium Bronze Cu Al10 Fe5 Ni5 250 280 600 650 13 13Cu Al11 Fe6 Ni6 320 380 680 750 5 5

Table 9.2.5 Visual and surface NDE acceptancecriteria for valves and pressurecomponents

Defect type Acceptance criteria for visual and surfaceNDE, see Note

Linear indications Not permitted

Porosity Individual pores are not to exceed 3 mm diameter bleed out, and the sum of the diameters of all indications in an area of 70 x 70 mm is not to exceed 24 mm2

NOTEInspection is to be in accordance with a procedure acceptable toLR.


2.9.1 Subject to the prior approval of the Surveyor, castings containing local porosity may be rectified by impreg-nation with a suitable plastic filler provided that the extent ofthe porosity is such that it does not adversely affect thestrength of the casting.

2.9.2 Proposals to repair a defective casting by weldingare to be submitted to the Surveyor before this work iscommenced. The Surveyor is to be satisfied that the number,position and size of the defects are such that the castings canbe efficiently repaired.

2.9.3 Where approval is given for the repair by welding,complete elimination of the defects is to be proven byadequate non-destructive testing.

2.9.4 All welding is to be in accordance with an approvedand qualified weld procedure and carried out by a qualifiedwelder.

2.9.5 A statement and/or sketch detailing the extent andposition of all weld repairs is to be prepared by the manufac-turer as a permanent record. These records are to beavailable for review by the Surveyor, and copies of individualrecords are to be supplied to the Surveyor on request.

2.9.6 The alloys listed in Table 9.2.1 are not satisfactoryfor repair by welding which is generally not permitted. Weldrepairs may, however, be considered in special circumstancesprovided that a suitable procedure, with proof of previoussatisfactory repairs is submitted to the Surveyor.

2.9.7 The welding during manufacture of liners is notpermitted in any alloy containing more than 0,5 per cent lead.


2.10.1 Where required by the relevant Rules, castings areto be pressure tested before final acceptance. Unless other-wise agreed, these tests are to be carried out in the presenceof the Surveyors and are to be to their satisfaction.

2.11 Identification

2.11.1 The manufacturer is to adopt a system of identifi-cation which will enable all finished castings to be traced tothe original cast, and the Surveyor is to be given full facilitiesfor tracing the casting when required.

2.11.2 Before acceptance, all castings which have beentested and inspected with satisfactory results are to be clearlymarked by the manufacturer with the following details:(a) Identification number, cast number or other markings

which will enable the full history of the casting to be traced.(b) LR or Lloyd’s Register and the abbreviated name of LR’s

local office.(c) Personal stamp of the Surveyor responsible for

inspection.(d) Test pressure, where applicable.(e) Date of final inspection.




2.12.2 The manufacturer is to provide the Surveyor withthe following particulars for each casting or batch of castingswhich has been accepted:(a) Purchaser’s name and order number.(b) Description of castings and alloy grade.(c) Identification number.(d) Ingot or cast analysis.(e) Full details of heat treatment, where applicable.(f) Mechanical test results.(g) Test pressure, where applicable.

2.12.3 In addition to 2.12.2, the manufacturer is to provide,where applicable, a statement and/or sketch detailing the extentand position of all weld repairs made to each casting.

■ Section 3Tubes

3.1 Scope

3.1.1 Provision is made in this Section for seamlesscopper and copper alloy tubes intended for use in condensers,heat exchangers and pressure piping systems.

3.1.2 Tubes for Class I and II pressure systems (asdefined in the relevant Rules) are to be manufactured andtested in accordance with the requirements of Chapters 1 and2 and the requirements of this Section.

3.1.3 As an alternative to 3.1.2, tubes which comply withNational or proprietary specifications may be acceptedprovided that these specifications give reasonable equiva-lence to the requirements of this Section or alternatively areapproved for a specific application. Generally, survey andcertification are to be carried out in accordance with therequirements of Chapter 1.

3.1.4 Tubes for Class III pressure systems are to bemanufactured and tested in accordance with the requirementsof a National or International Standard recognised by LR. Themanufacturer’s test certificate will be acceptable and is to beprovided for each batch of material.

3.2 Manufacture

3.2.1 Tubes for Class I and II pressure systems are to bemanufactured at a works approved by LR for the grade ofmaterial being supplied.

3.2.2 Tubes for Class III pressure systems are notrequired to be manufactured at a works approved by LR.




Copper Alloys

3.3 Quality

3.3.1 Tubes are to be clean and free from surface andinternal defects and residues from manufacturing operations.

3.3.2 The tubes are to be supplied in smooth, round,straight lengths and the manufacturer is to guarantee freedomfrom deleterious films in the bore. The ends are to be cut cleanand square with the axis of the tube and are to be de-burred.


3.4.1 The tolerances on the wall thickness and diameterof the tubes are to be in accordance with a National orInternational Standard recognised by LR.

3.4.2 The measurement of dimensional accuracy andcompliance with the specification are the responsibility of themanufacturer, but the reports are to be made available to theLR Surveyors, who may require checks to be made in theirpresence.


3.5.1 The chemical composition is to comply with therequirements of a National or International Standard recog-nised by LR and comply with the base limits for the principalelements given in Table 9.3.1.

3.6 Heat treatment

3.6.1 Copper-phosphorus and aluminium brass tubes areto be supplied in the annealed condition. Aluminium brasstubes may additionally be required to be given a suitablestress relieving heat treatment when subjected to a coldstraightening operation after annealing.

3.6.2 Tubes in the copper-nickel iron alloys are to besupplied in a solution heat treated condition to ensure that noiron rich phases are present.


3.7.1 Tubes are to be presented for test in batches of 300 lengths. A batch is to consist of tubes of the same size,manufactured from the same material grade.

3.7.2 At least one length is to be selected at random fromeach batch and subjected to the following tests:(a) Tensile test.(b) Flattening test.(c) Drift expanding test.

3.7.3 The procedures for mechanical tests and thedimensions of the test specimens are to be in accordancewith Chapter 2.

3.7.4 The flattening test is to be continued until the interior surfaces of the tube meet.

3.7.5 For the drift expanding test, the mandrel is to havean included angle of 45°.


3.7.7 At the discretion of the Surveyor, a modified testing procedure may be adopted for small quantities ofmaterials. In such cases, these may be accepted on themanufacturer’s declared chemical composition and hardnesstests or other evidence of satisfactory properties.




Chemical composition %Designation

Cu As P Fe Pb Ni Al Mn Zn

Copper-phosphorus 99,85 min. – 0,013–0,050 — — — — — —deoxidised–non-arsenical

Copper-phosphorus 99,2 min. 0,30–0,50 0,013–0,050 — — — — —deoxidised–arsenical

Aluminium brass 76,0–79,0 0,02–0,06 — 0,06 max. 0,07 max. — 1,8–2,5 — Remainder

90/10 Copper-nickel- Remainder — — 1,0-2,0 — 9,0–11,0 — 0,5–1,0 —iron (see Note)

70/30 Copper-nickel- Remainder — — 0,40–1,00 — 29,0–33,0 — 0,5–1,5 —iron (see Note)

NOTEWhere the purchaser specifies that the product is intended for subsequent welding applications, the following limits will apply:

Zn 0,50% max. S 0,02% max.Pb 0,02% max. C 0,05% max.P 0,02% max.

Table 9.3.1 Chemical composition of principal elements only


Chapter 9Section 3


Copper Alloys


3.8.1 All tubes are to be visually examined. The manufac-turer is to provide adequate lighting conditions to enable aninternal and external examination of the tubes to be carried out.

3.8.2 The inner and outer surfaces are to be clean andsmooth but may have a superficial, dull iridescent film on boththe inner and outer surfaces.

3.9 Hydraulic test

3.9.1 Each tube is to be subjected to a hydraulic test atthe manufacturer’s works.

3.9.2 The hydraulic test pressure is to be determinedfrom the following formula, except that the maximum testpressure need not exceed 70 bar:

P =

whereP = test pressure, in barD = nominal outside diameter, in mmt = nominal wall thickness, in mms = 40 for copper-phosphorus

60 for Al-brass and90/10 copper nickel iron75 for 70/30 copper nickel iron.

3.9.3 The test pressure is to be maintained for sufficienttime to permit proof that the tubes do not weep, leak orundergo a permanent increase in diameter. Unless otherwiseagreed, the manufacturer’s certificate of satisfactory hydraulictest will be accepted.

3.9.4 Where it is proposed to adopt a test pressure otherthan that determined in 3.10.2, the proposal will be subjectto special consideration.

20stD

3.9.5 Subject to special approval, an automated eddycurrent test can be accepted in lieu of the hydraulic test.Discontinuous irregularities on the external and internalsurfaces of the tubes are permitted if they are within theagreed dimensional tolerances, with the exception of cracks,which are not permitted.


3.10.1 The repair of defects by welding is not permitted.

3.11 Identification

3.11.1 Tubes are to be clearly marked by the manufacturerin accordance with the requirements of Chapter 1. The followingdetails are to be shown on all materials which have beenaccepted:(a) LR or Lloyd’s Register.(b) Manufacturer’s name or trade mark.(c) Grade of material or designation code.(d) Identification number and/or initials which will enable the

full history of the item to be traced.

3.11.2 Identification is to be by rubber stamp or stencils.Hard stamping is not permitted.


3.12.1 A manufacturer’s certificate validated by LR is to beissued (see Ch 1,3.1), giving the following particulars for eachcasting or batch of castings which has been accepted:(a) Purchaser’s name and order number.(b) Specification or grade of material.(c) Description and dimensions.(d) Cast number and chemical composition.(e) Mechanical test results.(f) Results of stress corrosion cracking test, where

applicable.(g) Hydraulic test report.

0,2% proof Tensile Elongation Drift expansion Grain sizeDesignation stress strength on 5,65 So test % mm

N/mm2 N/mm2 % minimum minimum maximumminimum minimum (see Note)

Copper-phosphorus 65 220 40 40 —deoxidised–non-arsenical

Copper-phosphorus 65 220 40 40 —deoxidised–arsenical

Aluminium brass 125 320 40 30 0,045

90/10 Copper-nickel-iron 100 270 30 30 0,045

70/30 Copper-nickel-iron 120 360 30 30 0,045

NOTEWhen a maximum grain size is specified, the structure is to be completely re-crystallised. The manufacturer is to guarantee the grain size, buttesting of each batch will not be required.


Section

1 Anchors

2 Stud link chain cables for ships

3 Stud link mooring chain cables

4 Studless mooring chain cables

5 Short link chain cables

6 Steel wire ropes

7 Fibre ropes

■ Section 1Anchors

1.1 Scope

1.1.1 This Section makes provision for the manufactureand testing of anchors constructed from cast, forged andfabricated components.

1.1.2 This Section is applicable to the following types ofanchor:(a) Ordinary.(b) High holding power (HHP).(c) Super high holding power (SHHP).

1.1.3 In the context of this Section, the reference toswivels refers to those directly attached to the anchor shankin lieu of the conventional ‘D’ shackle. For other mooringequipment swivels, see 2.13.

1.2 Manufacture

1.2.1 All anchors are to be of an approved design.

1.3 Cast steel anchors

1.3.1 Cast steel anchor heads, shanks, shackles andswivels are to be manufactured and tested in accordance withthe requirements of Ch 4,1 and Ch 4,2. The Special gradequality is to be used for anchor heads, shanks and shackles.

1.3.2 Special consideration will be given to the use ofother grades of steel for the manufacture of swivels.

1.3.3 To confirm the quality of cast anchor components,the Surveyor is to witness drop and hammering tests.

1.3.4 When drop and hammering tests are required, theyare to be carried out as follows:(a) Each anchor, or the components of an anchor made

from more than one piece, is to be dropped from a clearheight of 4 m onto a steel slab laid on a solid foundation.

(b) Separately cast flukes, shanks and shackles are to besuspended horizontally from a clear height of 4 m beforebeing dropped.

(c) Anchors cast in one piece are to be drop tested twicefrom a clear height of 4 m. For the first test, the shankand flukes are to be horizontal. For the second test, twosteel blocks are to be placed on the slab, arranged sothat the middle of each fluke makes contact with theblocks without the crown making contact with the slab,and the orientation of the anchor is to be vertical with thecrown nearest the slab.

(d) If the slab is broken by the impact, the test is to berepeated on a new slab.

1.3.5 When hammering tests are required, they are to becarried out after the drop test on each anchor head andshank, which is slung clear of the ground, using a non-metallic sling, and hammered to check the soundness of thecomponent. A hammer of at least 3 kg mass is to be used.

1.3.6 As part of the manufacturer’s works approval,consideration may be given to carrying out drop tests in alternative locations to the manufacturer’s when the facilitiesand location are not suitable.

1.3.7 Repair of fractures or unsoundness detected duringthe drop or hammering tests are not permitted and thecomponent is to be rejected.

1.4 Forged steel anchors

1.4.1 Forged steel anchor pins, swivels, shanks andshackles are to be manufactured and tested in accordancewith the requirements of Ch 5,1 and Ch 5,2 carbon andcarbon-manganese steel for welded construction. Rolled steelbar may be used provided that the requirements of Ch 5,1.2.9are met.

1.4.2 Special consideration will be given to other gradesof steel for the manufacture of swivels.

1.5 Fabricated steel anchors

1.5.1 Where it is proposed to use plate material for fabricated steel anchors, it is to comply with the requirementsof Ch 3,2 or Ch 3,3, and the proposed manufacturing procedure is to be submitted for approval.

1.5.2 Fabricated anchors are to be manufactured inaccordance with Chapter 13.

1.5.3 Stress relief is to be carried out as required in theapproved welding procedure.

1.6 Rectification

1.6.1 All rectification is to be agreed with the Surveyor.

1.6.2 Rectification of defective castings is to be carriedout in accordance with Ch 4,1.9.


Equipment for Mooring and Anchoring Chapter 10Section 1


1.6.3 Rectification of defective forgings is to be carriedout in accordance with Ch 5,1.9.

1.6.4 Rectification of defective fabricated anchors is tobe carried out by suitably qualified welders within the parameters of the approved welding procedure used inconstruction.

1.6.5 Rectification of defective castings, forgings or fabricated anchors by welding is to be carried out using qualified weld procedures in accordance with Ch 12,1 and Ch 12,2, and in accordance with Ch 13,1 and Ch 13,2.

1.7 Super high holding power (SHHP) anchors

1.7.1 The impact test requirements for SHHP anchorshackles are to be in accordance with the requirements forGrade U3 in Table 10.2.1.

1.8 Assembly

1.8.1 Assembly and fitting is to be carried out in accordance with the approved design.

1.8.2 Securing of anchor pins, shackle pins or swivels bywelding is to be carried out by suitably qualified welders inaccordance with an approved welding procedure.

1.9 Proof test of anchors

1.9.1 Anchors having a mass of 75 kg or more inclusiveof stock (56 kg in the case of high holding power anchors) areto be tested in the presence of the Surveyor at a provingestablishment recognised by LR. A list of recognised provingestablishments is published separately by LR. In addition tothe requirements stated in this Chapter, attention must begiven to any relevant statutory requirements of the NationalAuthority of the country in which the ship or mobile offshoreunit is to be registered.

1.9.2 The anchor is to be visually examined before application of the proof test load to ensure that it is free fromcracks, notches, inclusions and other surface defects thatwould impair the performance of the product.

1.9.3 As required by 1.9.1, each anchor is to besubjected to a proof loading test in an approved testingmachine and is to withstand the load given in Table 10.1.1 forthe appropriate mass of the anchor. The proof load is to beapplied on the arm or on the palm at a spot which, measuredfrom the extremity of the bill, is one-third of the distancebetween it and the centre of the crown. For stocked anchors,each arm is to be tested individually. For stockless anchors,both arms are to be tested at the same time, first on one sideof the shank, then reversed and tested on the other.

Mass Proof Mass Proof Mass Proofof test of test of test

anchor load anchor load anchor load(1.6.5) (1.6.5) (1.6.5)

kg kN kg kN kg kN

50 23,2 2200 376,0 7800 861,055 25,2 2300 388,0 8000 877,060 27,1 2400 401,0 8200 892,065 28,9 2500 414,0 8400 908,0

70 30,7 2600 427,0 8600 922,075 32,4 2700 438,0 8800 936,080 33,9 2800 450,0 9000 949,090 36,3 2900 462,0 9200 961,0

100 39,1 3000 474,0 9400 975,0120 44,3 3100 484,0 9600 987,0140 49,0 3200 495,0 9800 998,0160 53,3 3300 506,0 10 000 1010,0

180 57,4 3400 517,0 10 500 1040,0200 61,3 3500 528,0 11 000 1070,0225 65,8 3600 537,0 11 500 1090,0250 70,4 3700 547,0 12 000 1110,0

275 74,9 3800 557,0 12 500 1130,0300 79,5 3900 567,0 13 000 1160,0325 84,1 4000 577,0 13 500 1180,0350 88,8 4100 586,0 14 000 1210,0

375 93,4 4200 595,0 14 500 1230,0400 97,9 4300 604,0 15 000 1260,0425 103,0 4400 613,0 15 500 1280,0450 107,0 4500 622,0 16 000 1300,0

475 112,0 4600 631,0 16 500 1330,0500 116,0 4700 638,0 17 000 1360,0550 125,0 4800 645,0 17 500 1390,0600 132,0 4900 653,0 18 000 1410,0

650 140,0 5000 661,0 18 500 1440,0700 149,0 5100 669,0 19 000 1470,0750 158,0 5200 677,0 19 500 1490,0800 166,0 5300 685,0 20 000 1520,0

850 175,0 5400 691,0 21 000 1570,0900 182,0 5500 699,0 22 000 1620,0950 191,0 5600 706,0 23 000 1670,0

1000 199,0 5700 713,0 24 000 1720,0

1050 208,0 5800 721,0 25 000 1770,01100 216,0 5900 728,0 26 000 1800,01150 224,0 6000 735,0 27 000 1850,01200 231,0 6100 740,0 28 000 1900,0

1250 239,0 6200 747,0 29 000 1940,01300 247,0 6300 754,0 30 000 1990,01350 255,0 6400 760,0 31 000 2030,01400 262,0 6500 767,0 32 000 2070,0

1450 270,0 6600 773,0 34 000 2160,01500 278,0 6700 779,0 36 000 2250,01600 292,0 6800 786,0 38 000 2330,01700 307,0 6900 794,0 40 000 2410,0

1800 321,0 7000 804,0 42 000 2490,01900 335,0 7200 818,0 44 000 2570,02000 349,0 7400 832,0 46 000 2650,02100 362,0 7600 845,0 48 000 2730,0

Proof loads for intermediate mass are to be determined by linearinterpolation

NOTES

1. Where ordinary anchors have a mass exceeding 48 000 kg,the proof loads are to be taken as 2,059 (mass of anchor in kg)2/3 kN.

2. Where high holding power anchors have a mass exceeding36 000 kg, the proof loads are to be taken as 2,452 (actualmass of anchor in kg)2/3 kN.



LLOYD’S REGISTER2

Table 10.1.1 Proof load tests for anchors(see Notes 1 and 2)

1.9.4 The general arrangements for the test are to besuch that the complete anchor, including the shackle, shacklepins and any welded or bolted connections are included in thetest. If a replacement shackle is needed which requires welding or heating for fitting, the combined anchor andshackle are to be proof load tested. If welding or heating isnot involved in fitting, the shackle may be proof load testedseparately from the anchor.

1.9.5 The mass to be used in Table 10.1.1 is:(a) For stockless anchors, the total mass of the anchor.(b) For stocked anchors, the mass of the anchor excluding

the stock.(c) For high holding power anchors, a nominal mass equal

to 1,33 times the actual total mass of the anchor.(d) For mooring anchors, including positional mooring

anchors, a nominal mass equal to 1,33 times the actual total mass of the anchor, unless specifically agreedotherwise.

(e) For super high holding power anchors, a nominal massequal to twice the actual total mass of the anchor.

1.9.6 For positional mooring anchors, the proof test loading is to be that required by 1.9.3 or 50 per cent of theminimum break strength of the intended anchor line,whichever is the greater.

1.9.7 The gauge length is to be measured with 10 percent of the required load applied, before and after proof test.The two measurements shall differ by no more than 1 percent. The gauge length is the distance between the tip of eachfluke and a point on the shank adjacent to the shackle pin,see Fig. 10.1.1.

1.9.8 After proof testing, all accessible surfaces are to bevisually inspected by the Surveyor.

1.9.9 Following proof testing, NDE is to be conducted asdescribed in Table 10.1.2 for ordinary and HHP anchors andTable 10.1.3 for SHHP anchors.

1.9.10 Each casting is to be subjected to ultrasonicinspection in the region of runners and risers, or where excessmaterial has been removed by thermal methods. This exami-nation is to extend around the whole periphery of the castingand for a distance of t/3 beyond the area affected, where t isthe maximum thickness. In addition, random areas are to beselected by the Surveyor and examined.

1.9.11 Acceptance criteria for castings are to be in accor-dance with Chapter 4.

1.9.12 Acceptance criteria for forgings are to be in accor-dance with Chapter 5.

1.9.13 Paint or anti-corrosive coatings are not to beapplied until these inspections are completed to the satisfac-tion of the Surveyor.




Table 10.1.2 NDE requirements following proof testing for Ordinary and HHP anchors

Location Method of NDE

Feeder heads, runners and risers of castings Magnetic particle inspection and ultrasonic test, see Note 1

All welds Magnetic particle inspection

Forged components Not required

Fabrication welds Magnetic particle inspection

NOTES1. See also 1.9.10.2. Penetrant testing is to be used in lieu of magnetic particle testing for stainless steel, aluminium and copper alloy anchors.

Table 10.1.3 NDE requirements following proof testing for SHHP anchors

Location Method of NDE

Feeder heads, runners and risers of castings Magnetic particle inspection and ultrasonic test, see Note 1

All surfaces of castings Magnetic particle inspection

All welds Magnetic particle inspection

Forged components Not required

Fabrication welds Magnetic particle inspection

NOTES1. See also 1.9.10.2. Additionally, all surfaces of all SHHP anchors are to be surface inspected by the magnetic particle or penetrant method as appropriate.3. Penetrant is to be used in lieu of magnetic particle testing for stainless steel, aluminium and copper alloy anchors.

1.9.14 On completion of the proof testing, anchors madein more than one piece are to be examined for free movementof their heads over the complete range of rotation.

1.10 Clearances and tolerances

1.10.1 Where no fitting tolerances are specified on theapproved plans the following assembly and fitting toleranceare to be applied.

1.10.2 The clearance either side of the shank within theshackle jaws and the shackle pin in the shank end hole is tobe no more than 3 mm for small anchors up to 3 tonnes, 4 mm for anchors up to 5 tonnes, 6 mm for anchors up to 7 tonnes and is not to exceed 12 mm for larger anchors.

1.10.3 The shackle pin to hole tolerance is to be no morethan 0,5 mm for pins up to 57 mm and 1,0 mm for pins oflarger diameter and the eyes of the shackle are to bechamfered on the outside to ensure a good tightness whenthe pin is fitted. The shackle pin is to mate with the shacklesuch that it can be inserted with moderate hand pressure,allowing disassembly if required.

1.10.4 The trunnion pin is to fit within the chamber suchthat it will achieve the closest fit which can be carried out byhand. The pin is to be long enough to prevent horizontalmovement. The gap is to be no more than 1 per cent of thechamber length.

1.10.5 The lateral movement of the shank is not to exceed3 degrees from the centreline datum, see Fig. 10.1.2.

1.10.6 Unless otherwise agreed, the verification of massand dimensions is the responsibility of the manufacturer. TheSurveyor is only required to monitor this inspection. The massof the anchor is to exclude the mass of the swivel, unless theswivel is in lieu of the conventional ‘D’ shackle.

1.11 Identification

1.11.1 Identification marks on the shank are to be approx-imately level with the fluke tips. On the fluke, these markingsare to be approximately at a distance of two thirds from the tipof the bill to the centre line of the crown on the right handfluke, looking from the crown towards the shank.

1.11.2 The following details are to be shown on allanchors:(a) LR or Lloyd’s Register and abbreviated name of LR’s

local office issuing the certificate.(b) Number of the certificate.(c) Month and year of test.



LLOYD’S REGISTER4

3°

Fig. 10.1.2 Allowable lateral movement of shank

Stocked Anchor

Gauge length

L2 3

L

L1 3Stockless Anchor

Gauge length

L2 3

L

L1 3

Fig. 10.1.1 Location of gauge length measurement during proof load

2.1.3 The design of chain cables is to be to a Standardrecognised by LR, such as ISO 1704.

2.2 Manufacture

2.2.1 All grades of chain cable and accessories are to bemanufactured by approved procedures at works approved byLR. A list of approved manufacturers of stud link chain cablesand fittings is published separately by LR.

2.2.2 The links may be made by the flash-butt or otherapproved welding process, or in the case of Grades U2 andU3 they may be flash-butt welded or drop forged, designatedU2(a) or U3(a), or cast steel designated U2(b) or U3(b), seeTable 10.2.5.

2.2.3 As far as practicable, consecutive links in all chaincable should originate from a single cast or batch of bar stock(see Ch 3,9.6.1), and indicating marks should be stamped onthe final link formed from one cast or batch and the first linkformed from a separate cast or batch.

2.2.4 A length of chain cable is to measure not more than27,5 m and is to comprise an odd number of links. In thiscontext, a length is a statutory term and is the basis for thenumber of test samples.

2.2.5 Where end links or enlarged links are manufacturedand heat treated as part of and at the same time as the chaincable and are of the same cast heat of steel, they may beexcluded from separate mechanical tests and break loadtests.

2.3 Flash butt welded chain cable

2.3.1 Bar material is to comply with the requirements ofCh 3,9 and may be heated either by electrical resistance or ina furnace. For electrical resistance heating, the process is tobe controlled by an optical heat sensor. For furnace heating,thermocouples in close proximity to the bars are to be usedfor control. The temperature is to be continuously recorded. Inboth cases, the controls are to be checked at least once everyeight hours and checks are to be recorded.

2.3.2 Mechanical properties testing of U1 cable is notrequired. For Grade U2 cable supplied in the as-weldedcondition, and Grade U3 in all conditions, one tensile and oneset of three Charpy V-notch impact test specimens are to betaken at the side of a link opposite the weld from at least everyfourth 27,5 m length of cable. A further set of three impacttest specimens is to be taken with the notch positioned at thecentre of the weld, see Table 10.2.3. The test specimens arenot to be selected from the same length as that from whichthe breaking test sample is taken, unless breaking testsamples are to be taken from every length of the batch. Alltest samples are to be correctly identified with the lengths ofcable represented.

(d) Mass (also the letters ‘HHP’ when approved as highholding power anchors or ‘SHHP’ when approved assuper high holding power anchors).

(e) Mass of stock (in the case of stocked anchors).(f) National Authority requirements, as applicable.(g) Manufacturer’s mark.

1.11.3 In addition to 1.11.2, each important part of ananchor is to be plainly marked by the maker with the words‘forged steel’ or ‘cast steel’ as appropriate. Fabricated steelanchor heads do not require special marking.

1.12 Certification

1.12.1 The manufacturer is to provide the Surveyor with awritten statement that the anchor has been manufactured andtested in accordance with LR Rules together with the followingparticulars:(a) Purchaser’s name and order number.(b) Type of anchor and principal dimensions.(c) Mass of anchor.(d) Identification mark which will enable the full history of

manufacture to be traced.(e) Chemical composition.(f) Details of heat treatment.(g) Mechanical test results.(h) Proof load.(j) Results of the non-destructive examination.(k) Weld location maps (cast steel anchors only).

1.12.2 Shanks, heads, pins, shackles and swivels are tobe certified by LR in accordance with the relevant sections ofChapters 3, 4 and 5.

1.12.3 An LR Anchor Certificate is to be issued for thecompleted anchor which will include the following particulars:(a) Manufacturer’s name.(b) Type of anchor.(c) Mass of anchor.(d) Grade of materials.(e) Proof test load.(f) Heat treatment.(g) Marking applied to anchor.(h) Dimensions.(j) General Approval of an Anchor Design Certificate

Number.(k) Fluke and shank identification numbers.

■ Section 2Stud link chain cables for ships

2.1 Scope

2.1.1 Provision is made in this Section for a range ofgrades, U1, U2 and U3, of stud link chain and fittings intendedfor anchor cables for ships.

2.1.2 The requirements for mooring chain cables aregiven in Section 3.


Equipment for Mooring and Anchoring Chapter 10Sections 1 & 2


2.4.4 Tensile and Charpy V-notch impact test specimensare to be taken from each test sample and machined to thedimensions given in Ch 2,3.

2.4.5 The results of all tests are to comply with therequirements given in Table 10.2.1 for the relevant grade.

2.5 Forged chain cables

2.5.1 The procedure for the manufacture and testing ofdrop forgings for chain cable will be specially considered, butis generally to be in accordance with the appropriate require-ments of Ch 5,1.

2.5.2 The chemical composition is to comply with Table 10.2.2.

2.5.3 The completed forgings are to be heat treated inaccordance with Table 10.2.3.

2.5.4 Test samples are to be provided in the form offorgings of similar dimensions to the links they represent.These test samples are to be from the same steel-makingheat and heat treated together with the links they represent.

2.5.5 One tensile and three Charpy V-notch specimensare to be taken from each test sample.

2.3.3 The test links from which the mechanical test specimens are prepared are to be made as part of the chaincable and are to be heat treated with it. They may be removedfrom the cable prior to heat treatment provided that eachsample is heat treated with, and in the same manner as, thechain it represents prior to preparation of the mechanical testspecimens.

2.3.4 The results of tests on specimens taken from thenon-welded areas are to comply with the appropriate require-ments of Table 10.2.1. The results of tests on the welds are tocomply with the requirements of Table 10.2.6.

2.4 Cast chain cables

2.4.1 The manufacture of cast steel chain cable is generallyto be in accordance with the requirements of Ch 4,1, asappropriate.

2.4.2 The chemical composition of ladle samples is tocomply with the specification approved by LR.

2.4.3 Separately cast test samples are to be providedfrom each cast. They are to be of similar dimensions to thelinks they represent and are to be heat treated together with,and in the same manner as, the completed chain cable, seeTable 10.2.3.



LLOYD’S REGISTER6


Grade CSi Mn

P SAl

N Cr Cu Nb Ni V Momax. max. max. max. max. max. max. max. max. max.

U1 0,20 0,15 – 0,35 0,40 min. 0,04 0,04 — — — — — — — —

U2 0,24 0,15 – 0,55 1,60 max. 0,035 0,035 0,02 min. — — — — — — —see Note 1

U3 0,33 0,15 – 0,35 1,90 max. 0,04 0,04 0,065 max. 0,015 0,25 0,35 0,05 0,40 0,10 0,08see Note 2 see Note 2 see Note 2

NOTES1. Aluminium may be partly replaced by other grain refining elements.2. To obtain fine grain steel, at least one of these grain refining elements must be present in sufficient amount.

Table 10.2.2 Chemical composition of butt welded and forged chain cable

Charpy V-notchimpact tests

Yield stress Tensile strength Elongation ReductionGrade N/mm2 N/mm2 on 5,65 So of area Test Average

minimum % minimum % temperature energyminimum °C J minimum

U2 295 490 – 690 22 — 0 27(see Note 1)

U3 410 690 minimum 17 40 0 60–20 35

(see Note 2)

NOTES1. When required see Table 10.2.3.2. Testing may be carried out at either 0°C or –20°C.3. Mechanical testing is not required for finished chain cables and fittings in Grade U1.

Table 10.2.1 Mechanical properties of finished chain cable and fittings

2.5.6 The results of mechanical tests are to comply withthe requirements of Table 10.2.1 for the relevant grade.

2.6 Stud material

2.6.1 Steel studs are to be used for all grades of weldedchain cable. In general, the carbon content should not exceed0,23 per cent but mechanical tests for acceptance purposesare not required.

2.7 Welding of studs

2.7.1 Where studs are welded into the links this is to becompleted before the chain cable is heat treated.

2.7.2 The stud ends must be a good fit inside the link,and the weld is to be confined to the stud end opposite theflash-butt weld. The full periphery of the stud end is to bewelded. If, however, it can be demonstrated to the Surveyorthat the quality of welding is of a high standard then partialperipheral welding may be accepted provided that welds aremade only at the sides of the stud and that each run extendscontinuously for at least 25 per cent of the stud periphery.Weld start/stop positions are not to be located in the plane ofthe chain cable.

2.7.3 The welds are to be made by qualified weldersusing an approved procedure and consumables approved to Grade 3 and low hydrogen, in accordance with Chapter 11.

2.7.4 The welds are to be of good quality and free fromdefects liable to impair the proper use of the chain. Undercuts,end craters and similar stress raising defects shall, wherenecessary, be ground off.

2.7.5 At least one stud weld within each length of cable isto be inspected using dye penetrant testing in accordancewith Ch 1,5 after the chain has been proof loaded. If a crackis found, the stud welds in the adjoining links are to beinspected; if a crack is found in either link, all the stud weldsin that length are to be inspected using dye penetrant.

2.8 Heat treatment of completed chain cables

2.8.1 The completed chain cable is to be heat treated inaccordance with Table 10.2.3 for the appropriate grade ofcable.

2.8.2 Special consideration will be given to the heat treatment of certain types of drop forged chain cable.

2.8.3 In all cases, heat treatment is to be carried out priorto the proof loading and breaking tests.

2.8.4 All test samples are to be heat treated with, and inthe same way as, the chain cables they represent.

2.9 Testing of completed chain cables

2.9.1 All chain cables are to be subjected to a Proof Loadtest and a Breaking Load test. In addition, mechanical testsshould be carried out where required, see Table 10.2.3.




Table 10.2.3 Condition of supply and scope of mechanical tests for finished chain cables and fittings

Grade

U1cable

U2cable

U3cable

U2cable

U3cable

U2 fittings

U3fittings

Manufacturingmethod

Flash buttwelded

Flash buttwelded

Flash buttwelded

Cast or dropforged

Cast or drop forged

Cast or drop forged

Cast or dropforged

Condition of supply

As weldedNormalised

As weldedNormalised

NormalisedNormalised and TemperedQuenched and Tempered

Normalised


Normalised


Tensile test on basematerials

——

1—

1

1

1

1

1

Number of test specimens on every four lengths of chain cable of 27,5 m or less, or on each batch of fittings

Charpy V-notch impact test

Base material

— —

3—

3

3

3

3

3

Weldment

— —

3—

3

—

—

—

—

2.11.6 If more than one link in a 27,5 m length of chaincable fails to meet the tolerance requirements, all the links inthat length are to be measured.

2.11.7 Links that fail to comply with tolerance require-ments are to be removed and approved connecting linksinserted. Where a significant number of links fail to complywith the tolerance requirements the chain is to be rejected.

2.11.8 The form and proportion of links and shackles areto be in accordance with a standard recognised by LR, suchas ISO 1704; alternatively, the design may be specificallyapproved by LR.

2.11.9 Manufacturing tolerances on stud link chain are tobe within ±2,5 per cent (taking into account that all compo-nents of the chain are to be a good fit with one another),except for those detailed in 2.11.10.

2.11.10 The nominal diameter, d, is to be the average of thediameters, measured in the plane of the link, dc, and perpen-dicular to the plane of the link, dp, see Fig. 10.2.1. Thenegative tolerance on the nominal diameter is not to exceedthe following:

Minus 1 mm when d ≤ 40 mmMinus 2 mm when 40 mm < d ≤ 84 mmMinus 3 mm when 84 mm < d ≤ 122 mmMinus 4 mm when d > 122 mm

The plus tolerance on the diameter at the crown measuredout of the plane of the link, dp, is not to exceed 5 per cent.

2.11.11 The cross-sectional area is to be calculated usingthe nominal diameter, d. The cross-sectional area at thecrown of the link is to have no negative tolerance.

2.11.12 The diameter measured at locations other than thecrown is to have no negative tolerance. The plus tolerance isto be in accordance with Table 3.9.3 in Chapter 3 except atthe butt weld where it is to be in accordance with the manu-facturer’s specification, which is to be agreed by LR.

2.9.2 All chain cables are to be tested in the presence ofa Surveyor, at a proving establishment recognised by LR. Alist of recognised proving establishments is published separately by LR. In addition to the requirements stated in thisChapter, attention must be given to any relevant statutoryrequirements of the National Authority of the country in whichthe ship is to be registered.

2.10 Proof load tests

2.10.1 Each length of chain cable is to be subjected to aproof loading test in an approved testing machine and is towithstand the load given in Table 10.2.4 for the appropriategrade and size of cable.

2.10.2 On completion of the test, each link is to be visually examined and is to be free from significant defects.Special attention is to be given to welds.

2.10.3 Should any link be found to be defective it is to bereplaced by an approved connecting link (joining shackle orsubstitute link as detailed in 2.14). The chain is then to besubjected to a repeat of the proof load test followed by re-examination.

2.10.4 If a link breaks during proof load testing, a sampleconsisting of three common links is to be taken from eachside of the broken link and subjected to a breaking test asdetailed in 2.12. If either of these samples fails, the length ofcable is not to be accepted. A thorough examination of allbroken links is to be made to determine the cause of failureand, after evaluation, LR will consider the extent of cablewhich is to be rejected.

2.11 Dimensional inspection

2.11.1 The measurement of dimensions in 2.11.2 and2.11.3 is to take place after the proof load has been applied tothe chain and subsequently reduced to the load of 10 per centof the proof load. All other dimensional checks are to becarried out without application of load.

2.11.2 On every 27,5 m length of chain, five links are to beselected for measurement of length to ensure that the maxi-mum allowable tolerance on a length of five links is plus 2,5per cent. No under-tolerance is permitted.

2.11.3 If a five-link length of chain exceeds the tolerancegiven in 2.11.2, then the entire chain is to be checked forlength, five links at a time with an overlap of two links, whichis to include the first five links. Oversize links are to beremoved and an approved connecting link inserted.

2.11.4 Checks of all other dimensions are to be made onthree links from every four 27,5 m lengths. All measurementsare to be made on links selected by the Surveyor and are tobe carried out to the Surveyor’s satisfaction.

2.11.5 If one of the links detailed in 2.11.4 fails to complywith the required tolerances, measurements are to be madeon all four 27,5 m lengths.



LLOYD’S REGISTER8

α

a

A

d

dp

Off-centre distance:

X = A – a

2

Fig. 10.2.1 Manufacturing tolerances




Grade U1 Grade U2 Grade U3Chaindiameter Proof load kN Breaking load kN Proof load kN Breaking load kN Proof load kN Breaking load kN

d mm 0,00686d2 0,00981d2 0,00981d2 0,01373d2 0,01373d2 0,01961d2

(44– 0,08d) (44– 0,08d) (44– 0,08d) (44– 0,08d) (44– 0,08d) (44– 0,08d)

12,5 46 66 66 92 — —14 58 82 82 115 — —16 75 107 107 150 — —

17,5 89 128 128 179 — —19 105 150 150 211 — —

20,5 122 175 175 244 244 34922 140 201 201 281 281 40124 166 238 238 333 333 47526 194 278 278 389 389 55628 225 321 321 450 450 642

30 257 367 367 514 514 73432 291 416 416 583 583 83234 327 468 468 655 655 93636 366 523 523 732 732 104538 406 580 580 812 812 1160

40 448 640 640 896 896 128042 492 703 703 984 984 140644 538 769 769 1076 1076 153746 585 837 837 1171 1171 167348 635 908 908 1270 1270 1814

50 686 981 981 1373 1373 196152 739 1057 1057 1479 1479 211354 794 1135 1135 1589 1589 226956 850 1216 1216 1702 1702 243058 908 1299 1299 1818 1818 2597

60 968 1384 1384 1938 1938 276762 1029 1472 1472 2060 2060 294364 1092 1562 1562 2187 2187 312366 1157 1655 1655 2316 2316 330868 1223 1749 1749 2448 2448 3496

70 1291 1846 1846 2583 2583 369073 1395 1995 1995 2792 2792 398876 1503 2149 2149 3007 3007 429578 1576 2254 2254 3154 3154 450581 1689 2415 2415 3380 3380 4827

84 1805 2580 2580 3612 3612 515887 1923 2750 2750 3849 3849 549890 2045 2924 2924 4093 4093 584592 2127 3042 3042 4258 4258 608195 2254 3223 3223 4510 4510 6442

97 2339 3345 3345 4682 4682 6687100 2470 3532 3532 4943 4943 7060102 2558 3658 3658 5120 5120 7312105 2692 3850 3850 5389 5389 7697107 2783 3980 3980 5571 5571 7957

111 2968 4245 4245 5941 5941 8486114 3110 4447 4447 6224 6224 8889117 3253 4652 4652 6511 6511 9299120 3398 4859 4859 6801 6801 9714122 3496 4999 4999 6997 6997 9994

124 3595 5141 5141 7195 7195 10276127 3744 5354 5354 7494 7494 10703130 3895 5571 5571 7796 7796 11135132 3997 5716 5716 8000 8000 11426137 4254 6083 6083 8514 8514 12161

142 4515 6456 6456 9036 9036 12906147 4779 6834 6834 9565 9565 13662152 5046 7217 7217 10100 10100 14426157 5316 7602 7602 10640 10640 15197162 5588 7991 7991 11185 11185 15975

Table 10.2.4 Test loads for stud link anchor chain cables

2.11.13 Studs must be located in the links centrally and atright angles to the sides of the link, although the studs at eachend of any length may also be located off-centre to facilitatethe insertion of the joining shackle. The following tolerancesin Fig. 10.2.1 will be accepted provided that the stud fitssnugly and its ends lie practically flush against the inside ofthe link:

Maximum off-centre distance ‘X’: 10 per cent of thenominal diameter dMaximum deviation ‘α’ from the 90° – position: 4°.

2.11.14 All individual parts must have a clean surfaceconsistent with the method of manufacture and the surface isto be free from cracks, notches, inclusions and other defectswhich could impair the performance of the product. Crack-like imperfections less than 3 mm in length can be ignored.The flash produced by upsetting or drop forging must beproperly removed.

2.11.15 Minor surface imperfections may be ground off soas to leave a gentle transition to the surrounding surfaceprovided that the cross-sectional area remains equal to orgreater than the nominal cross-sectional area. Remote fromthe crown, local grinding up to 5 per cent of the nominal diameter may be permitted.

2.11.16 Paint or anti-corrosive coatings are not to beapplied until these inspections are completed to the satisfactionof the Surveyor.

2.12 Breaking load tests

2.12.1 Breaking load tests are to be carried out on three-link samples selected by the Surveyor from the completed(including heat treatment) chain. The test links may beremoved from the chain prior to heat treatment provided thateach sample is heat treated with, and in the same manner asthe chain it represents. They are to be properly identified withthe lengths of chain they represent.

2.12.2 The number of tests required is to be in accordancewith Table 10.2.5 except that for chafing chain for EmergencyTowing Arrangements (ETA), see Pt 3, Ch 13,10.2, one test isto be carried out on each 110 m of finished chains.

2.12.3 Breaking test specimens are to withstand the loadgiven in Table 10.2.4 for the appropriate grade and size ofcable. The specimen is considered to have passed this test ifit has shown no sign of fracture after application of therequired load for a minimum of 30 seconds.

2.12.4 Where a breaking test specimen fails, a furtherspecimen is to be cut from the same length of cable andsubjected to test. If this re-test fails, the length of cable fromwhich it was taken is to be rejected. When this test is alsorepresentative of other lengths, each of the remaining lengthsis to be individually tested by taking a breaking test specimenfrom each length of the batch. If one of these further testsfails, the entire set of lengths represented by the original testis to be rejected.

2.12.5 For large diameter cables where the required breaking load is greater than the capacity of the testingmachines, special consideration will be given to acceptanceof an alternative testing procedure.

2.13 Fittings for chain cables

2.13.1 Cable fittings are to be manufactured at anapproved works.

2.13.2 The materials from which the fittings are made areto be manufactured at approved works, in accordance withthe appropriate requirements of Ch 4,1 or Ch 5,1 respectively.Alternative arrangements may be agreed provided that fulldetails concerning the manufacturer are submitted to LR.




DesignationMethod of Number of breaking

manufacture test specimens

Grade U1 Flash-butt welded and One from every fourheat treated lengths of 27,5 m

or less

Grade Flash-butt welded, One from every fourU2(a) or drop forged lengths of 27,5 mU3(a) and heat treated or less

Grade U1 Flash-butt welded One from each lengthU2(a) but not heat of 27,5 m or less

treated

Grade U2(b) Cast and heat treated One per heatU3(b) treatment batch

with a minimumof one from everyfour lengths of27,5 m or less

Table 10.2.5 Number of breaking tests fromcompleted cables

Charpy V-notchimpact test

GradeTest Average

temperature energy°C J min

U1 — —U2 0 27

(see Note 1)U3 0 50

–20 27(see Note 2)

NOTES1. Impact tests are only required if the chain cable is not heat

treated.2. Impact testing may be carried out at 0°C or minus 20°C.

Table 10.2.6 Mechanical properties of welds inchain cables

2.13.3 All fittings are to be manufactured to an approvedmanufacturing specification, and provision is to be made fortensile specimens and, where applicable, impact test specimens, see Table 10.2.3. The mechanical test require-ments are the same as those for the relevant grade of chaincable, see Table 10.2.1.

2.13.4 The test samples are to be prepared in accordancewith 2.4.3 or 2.5.4 as applicable. The test specimens are tobe subjected to heat treatment with the fittings theyrepresent.

2.13.5 For mechanical testing, a batch is defined asfittings of the same grade, size and heat treatment furnaceload and is to have originated from a single cast heat of steel.

2.13.6 Mechanical tests of pins are to be taken inaccordance with 3.8.15.

2.13.7 Fittings such as shackles, swivels and swivelshackles are to be forged or cast in steel of at least GradeU2. The welded construction of fittings may also be approvedproviding that full details of the manufacturing process andthe heat treatment are submitted.

2.13.8 All chain cable accessories, including spares, are tobe subjected to the proof loads appropriate to the grade andsize of cable for which they are intended. These includeshackles, swivels, swivel shackles, enlarged links and endlinks. Anchor shackles, however, are to be tested in combinationwith the anchor, see 1.4.

2.13.9 The appropriate breaking load is to be applied fora minimum of 30 seconds to at least one item out of everybatch of up to 25 detachable links, shackles, swivels, swivelshackles, enlarged end links and end links and at least oneitem out of every batch of up to 50 for lugless (Kenter) shackles. The item tested is to be destroyed and not used aspart of an outfit. For the purposes of break load testing, abatch of accessories is to consist of:(a) the same accessory type, grade and size;(b) the same rolling or forging or casting process; and(c) accessories that are heat treated together in the same

furnace.

2.13.10 Where a break load batch as defined in 2.13.9requires a normalise or normalise and temper heat treatment,the size of accessories may vary within a batch provided thatthe heat treatment cycle is chosen to satisfy the accessorywith the largest cross-section size. The batch may consist ofmore than one steel-making heat provided that the twoaccessories are break tested, one with the largest cross-section size and one with the smallest cross-section size.

2.13.11 Where a break load batch as defined in 2.13.9requires a quench and temper heat treatment, the size of theaccessories within the batch is to be the same and is limitedto the same steel-making heat.

2.13.12 If the sample fails to withstand the breaking load with-out fracture, two more samples from the same batch may betested. If either of these samples fails, the batch is to be rejected.

2.13.13 Fittings of increased dimensions or higher gradematerial may be used subject to approval by LR.

2.13.14 Where items of increased dimensions are used or ifmaterial of a higher grade than is specified is used, the breakingload is to be applied to each item, and the items so testedincluded with the outfit. For the purpose of this paragraph, itemsof increased dimensions are those so designed that their break-ing strength is not less than 1,4 times the Rule minimumbreaking load of the chain cable with which they are to be used.

2.13.15 LR may waive the breaking load test provided that:(a) the breaking load test has been completed satisfactorily

during approval testing, and(b) the tensile and impact properties of each manufacturing

batch are proved and(c) the accessories are subjected to suitable non-destructive

testing.

2.13.16 All testing is to be carried out in the presence of theSurveyor and to his satisfaction.

2.13.17 The following tolerances are applicable toaccessories:

Nominal diameter: plus 5 per cent, minus 0 per cent Other dimensions: ±2,5 per centThe radii of all machined corners are to be not less than0,03 times the nominal chain diameter.

2.13.18 All fittings are to be stamped in accordance with2.15.

2.14 Substitute single links

2.14.1 Single links to connect lengths of chain cable or tosubstitute for defective links, without the necessity for re-heat treatment of the whole cable length, are to be madeby the chain manufacturer in accordance with an approvedprocedure. Separate approvals are required for each grade ofchain cable and the tests are to be made on the maximumsize of chain for which approval is sought. Re-approval isrequired annually.

2.14.2 Manufacture and heat treatment of the substitutelink are not to affect the strength of the adjoining links. Thetemperature reached by these links is nowhere to exceed250°C.

2.14.3 The steel bar used is to conform with the specificationfor the chain in accordance with Ch 3,9.

2.14.4 Details of the method of manufacture, includingheat treatment, are to be submitted for approval, togetherwith the results of a series of tests laid down by LR.

2.14.5 All links involved in the approval tests are to bedestroyed and are not to be used as part of a chain cable.

2.14.6 Every substitute link included in a chain cable is tobe subjected to the proof load appropriate to the grade andsize of chain in which it is incorporated, as detailed in Table 10.2.4.




2.14.7 Each substitute link is to be stamped on the studwith the identification marks listed in 2.15.1 plus a uniquenumber for the link. The adjoining links are also to be stampedon the studs.

2.15 Identification

2.15.1 All lengths of Grades U1, U2 and U3 cable and allfittings are to be stamped with the following identificationmarks:(a) LR or Lloyd’s Register and abbreviated name of LR’s

local office issuing the certificate.(b) Number of certificate.(c) Proof load and grade of chain.(d) Surveyor’s personal stamp.(e) Each length of chain cable is to be stamped on both

ends.

2.16 Certification

2.16.1 An LR certificate is to be issued for chain cable only,fittings only or chain cable with associated fittings.

2.16.2 Each test certificate is to include the following particulars for all items included on the certificate:(a) Manufacturer’s name.(b) Purchaser’s name and order number.(c) Description and dimensions.(d) Grade of chain cable.(e) Identification mark which will enable the full history of the

chain or fitting to be traced.(f) Chemical composition.(g) Details of heat treatment.(h) Mechanical test results.(j) Breaking test load.(k) Proof load.

2.16.3 Where appropriate, the certificate is to include a listof all substitute links together with their grade of steel, thename of the steelmaker, the heat number and the purchaseorder number.




d = nominal diameter of common stud linkd2 = nominal diameter of end link = 1,2d (d2 = 1,2d)l2 = p2 + 2d2 ≈ 6,75dp2 = 3,65d2 ≈ 4,35dw2 = 3,3d2 ≈ 4d

1,6d

φd2

p2 l2

w2

Fig. 10.2.4 End link

dc

p l

w

1,3dc

dp

d = nominal diameter

dc = nominal diameter at crown measured in plane of link dp = nominal diameter at crown measured perpendicular to plane of link l = 6dc p = 4dc w = 3,6dc to the nearest millimetre

( )dc + dp2

Fig. 10.2.2 Common link

p1 l1

w1

1,43d

φd1

d = nominal diameter of common stud linkd1 = nominal diameter of enlarged stud link = 1,1dl1 = 6d1 ≈ 6,6dp1 = 4d1 ≈ 4,4dw1 = 3,6d1 ≈ 3,96d

Fig. 10.2.3 Enlarged link




Key1 retaining pin2 dovetail chamber

d = nominal diameter of common stud link f1 = 2,8dd3 = nominal diameter of joining shackle = 1,3d g1 = 0,2dl3 = 7,1d g2 = 0,1dp3 = l3 – (d3 + a1 + e1) = 3,4d h1 = nominal diameter of taper pinw3 = 4d h2 = nominal length of taper pina1 = 0,8d R1 = 0,6de1 = 1,6d R2 = 0,5d

φd3

p3

e1

a1

f1

R2

R1

g1 d3

w3

l3

g2g1

1 2

h1h1h2

φh1

h1

h1/4

h1/4

Detail X

Detail Y

Detail X

Detail Y

Fig. 10.2.5 Dee shackle




Key1 retaining pin2 dovetail chamber

d = nominal diameter of common stud link f2 = 3,1dd5 = nominal diameter of end shackle = 1,4d g1 = 0,2dl5 = 8,7d g2 = 0,1dp5 = l5 – (d5+ a2 + e2) = 4,5d m = 1,4dw5 = 5,2d h1 = nominal diameter of taper pina2 = 0,9d h2 = nominal length of taper pine2 = 1,8d

φd5

p5

e2

a2

f1

g1 d5

w5

l5

g1g1

1 2

h1h2

φh1

h1

h1/4

h1/4

m

2,4d

Detail X

Detail X

Detail Y

Detail Y

r

r

Fig. 10.2.6 End shackle




d = nominal diameter of common stud link d1 = nominal diameter of Kenter type joining shackle = d l4 = 6d p4 = 4d w4 = 4,2d h1 = nominal diameter of taper pin h2 = nominal length of taper pin k = 1,52d R3 = 0,67d R4 = 1,83d

w4

l4

R3R4 k

φd4

p4

φh1

h2

h1

15°

h1/4

h1/4 h1

Detail Y

Detail X

= dovetail chamber for retaining pelletKey

Detail X

Fig. 10.2.7 Lugless shackle

d = nominal diameter of common stud link d6 = nominal diameter of swivel = 1,2d l6 = 9,7d p6 = d9 = 3,4d w6 = 4,7d d7 = 1,1d a3 = 1,75d m1 = 2d h3 = d8 = 1,4d c = 3,35d

w6

m1

c

h3

a3

p6

l6

d8

d9

φd6

φd7

Fig. 10.2.8 Swivel

d4r

r

The radii indicated by r are to be not less than 0,03 x d4

Fig. 10.2.9 Lugless shackle of the Kenter type

3.2.9 As far as practicable, consecutive links in all chaincable should originate from a single batch of bar stock (seeCh 3,9.6.1) and indicating marks should be stamped on thefinal link formed from one batch and the first link formed froma separate batch.

3.3 Dimensions and tolerances

3.3.1 The form and proportions of links and shackles areto be in accordance with ISO/1704, see Figs. 10.2.2 to10.2.9. Link tolerances are to be in accordance with 3.3.2 to3.3.6.

3.3.2 Diameter measured at the crown:Minus 1 mm when dc ≤ 40 mmMinus 2 mm when 40 mm < dc ≤ 84 mmMinus 3 mm when 84 mm < dc ≤ 122 mmMinus 4 mm when 122 mm < dc ≤ 152 mmMinus 6 mm when 152 mm < dc ≤ 184 mmMinus 7,5 mm when 184 mm < dc ≤ 210 mm

The plus tolerance must not exceed 5 per cent of the nominaldiameter, and the cross-sectional area at the crown is to haveno negative tolerance.

3.3.3 The diameter measured at locations other than thecrown is to have no negative tolerance. The plus tolerance isto be in accordance with Table 3.9.3 except at the butt weldwhere it is to be in accordance with the manufacturer’s specification, which is to be agreed by LR.

3.3.4 The maximum allowable tolerance on a length offive links measured in accordance with 2.11.1 is +2,5 percent. No under-tolerance is permitted.

3.3.5 A manufacturing tolerance on all other dimensionsof ±2,5 per cent is acceptable subject to all parts fitting properly together.

3.3.6 The tolerances for common links are to bemeasured in accordance with Fig. 10.3.2.

3.3.7 All measurements are to be made on links selectedby the Surveyor and are to be carried out to the Surveyor’ssatisfaction.

3.3.8 Studs are to be located in the links centrally, and atright angles to the sides of the link, although the studs of thefinal link at each end of any length may also be located off-centre to facilitate the insertion of the joining shackle. Thetolerances in accordance with Fig. 10.3.2 are acceptableprovided that the stud fits snugly and its ends lie flush againstthe inside of the link.

3.4 Studs

3.4.1 The studs are to be made of steel corresponding tothat of the chain or in compliance with a specificationapproved by LR. In general, the carbon content should notexceed 0,23 per cent if the studs are to be welded in place.

■ Section 3Stud link mooring chain cables

3.1 Scope

3.1.1 Provision is made in this Section for five grades,R3, R3S, R4, R4S and R5, of stud link chain intended foroffshore mooring applications such as mooring of mobileoffshore units, offshore loading systems and gravity basedstructures during fabrication.

3.1.2 Design of chain cables must be to a recognisedStandard, such as ISO 1704; alternatively, the design may bespecifically approved by LR.

3.1.3 In addition, chain cable conforming to the require-ments of the current edition of API specification 2F is acceptableprovided that it has been manufactured, inspected and testedunder Survey by LR, and that the bar stock has also beencertified by LR in accordance with Ch 3,9.

3.2 Manufacture

3.2.1 All grades of chain cable and accessories are to bemanufactured by approved procedures at works approved byLR. A list of approved manufacturers for stud link chain cablesis published separately by LR.

3.2.2 The works in which the chain is manufactured is tohave a quality system approved by LR. The provision of sucha quality system is required in addition to and not in lieu of thewitnessing of tests by a Surveyor.

3.2.3 Approval is confined to a single works and is limitedto one grade of cable made from bar from a nominated andapproved supplier. Separate approvals are required if steel baris supplied from more than one works and for other gradesof cable, see also Ch 3,9.

3.2.4 Details of the method of manufacture and the specification of the steel, are to be submitted.

3.2.5 Offshore mooring chains are to be made in continuous lengths by flash-butt welding.

3.2.6 Bar material may be heated either by electric resistance or in a furnace. For electrical resistance heating,the process is to be controlled by an optical heat sensor. For furnace heating, thermocouples in close proximity to the barsare to be used for control and the temperature is to be continuously recorded. In both cases, the controls are to bechecked at least once every eight hours and records taken.

3.2.7 The following welding parameters (as approved inthe weld procedure) are to be controlled during welding ofeach link:(a) platen motion;(b) current as a function of time; and(c) hydraulic pressure.The controls are to be checked at least once every four hours.

3.2.8 The records of bar heating, flash-butt welding andheat treatment are to be made available to the Surveyor whenrequired.




3.4.2 Studs may be welded into grade R3 and R3Schains. The welding of studs into grade R4, R4S and R5 chainis not permitted unless specially approved.

3.4.3 In all cases where studs are welded into links, this isto be carried out in accordance with 2.7.

3.4.4 The size of the stud welds is to be in accordancewith Fig. 10.3.1.

3.4.5 All stud welds are to be visually inspected. At least10 per cent of all stud welds within each length of chain are tobe examined by magnetic particle inspection after proof loadtesting. Stress raising defects such as cracks, lack of fusion,gross porosity, and undercuts exceeding 1 mm are notpermitted; if any such defects are found, then all stud welds inthat length of chain are to be examined by means of magneticparticle inspection.

3.4.6 Where plastic straining is used to set studs, theapplied load is not to be greater than that qualified in approvaltests. The combined effect of shape and depth of the impression of the stud in the link is not to cause any harmfulnotch effect or stress concentration.

3.5 Heat treatment of completed chain cables

3.5.1 The chain is to be normalised, normalised andtempered or quenched and tempered in accordance with thespecification approved by LR.

3.5.2 The chains are to be heat treated in a continuousfurnace; batch heat treatment is not permitted.

3.5.3 The temperature and time, or temperature andchain speed, are to be controlled and continuously recorded.

3.5.4 Heat treatment is to be carried out prior to the proofloading and breaking tests.

3.5.5 Calibration of furnaces is to be verified by measure-ment and recording of actual link temperature (surface andinternal).

3.6 Testing of completed chain cables

3.6.1 All chain cables are to be tested in the presence ofa Surveyor, at a proving establishment recognised by LR. Alist of recognised proving establishments is published by LR.In addition to the requirements stated in this Chapter, attention must be given to any relevant statutory requirementsof the National Authority of the country in which the ship is tobe registered.

3.6.2 The entire length of chain cable is to be subjectedto a proof loading test in an approved testing machine and isto withstand the load given in Table 10.3.1 for the appropriategrade and size of cable.

3.6.3 Care should be taken to obtain a uniform stressdistribution in the links being tested.

3.6.4 The chain is to be shot or sand blasted prior to test-ing in order to ensure that its surfaces are free from scale,paint or other coating for inspection.

3.6.5 On completion of the proof load test, each link is tobe visually examined and is to be free from significant defectssuch as mill defects, surface cracks, dents and cuts, especially where gripped by clamping dies during flash buttwelding. Studs are to be securely fastened and any burrs,irregularities and rough edges are to be removed by carefulgrinding.

3.6.6 All flash butt welds, including the area gripped bythe clamping dies, are to be examined by magnetic particleinspection. The area is to be free from cracks, lack of fusion,gross porosity and any other stress concentrations.

3.6.7 Surface defects in the region of the flash butt weldsmay be removed by grinding, provided that the depth ofgrinding does not exceed five per cent of the link diameterand is smoothly contoured into the surrounding material. Thefinal dimensions are still to conform with the agreed standard.

3.6.8 All flash butt welds are also to be examined byultrasonic inspection and are to be free from defects such asinternal cracks or lack of fusion.

3.6.9 All non-destructive examination is to be carried outin accordance with approved procedures, in accordance withCh 1,5.

3.6.10 All non-destructive examination operators are to bequalified to a minimum Level II, qualified in accordance with arecognised standard.

3.6.11 After proof testing, the entire chain is to be checkedfor length, five links at a time with an overlap of two links,which is to include the first five links, to ensure that the chainmeets the tolerances given in 2.11.12. The measurements areto be made while the chain is loaded to about 10 per cent ofthe proof load.




f 90°

g

h

DimensionDesignation

NominalDimension

MinusTolerance

fgh

0,10d0,20d0,09d

0,01d0,02d0,01d

3450/02d = Nominal diameter of barstock

Fig. 10.3.1Dimensions and tolerances of stud welds

3.6.12 The links held in the end blocks may be excludedfrom these measurements.

3.6.13 If the length over five links is less than the nominal,the chain may be stretched by loading above the specifiedproof test load provided that the applied load is not greaterthan ten per cent above the proof test load, and that onlyrandom lengths of the chain need to be stretched.

3.6.14 Loads used for plastic straining to set studs are notto exceed those approved in qualification tests.

3.6.15 Checks of all other dimensions are to be made onat least five per cent of the links in the cable.

3.6.16 If any link fails to meet the dimensional tolerancerequirements (see 3.3), measurements are to be made on 20 more links on each side of the incorrect one. If failure tomeet any particular dimensional requirements occurs in morethan two of the measured links, then all the links are to be dimensionally checked.

3.6.17 Should any link be found to be defective or fail tomeet the dimensional tolerance requirements or if a five linklength of chain exceeds the specified tolerance, the unsatis-factory links are to be removed from the chain, andconnecting common links complying with the requirements of3.7 inserted in their places.

3.6.18 The chain is then to be subjected to a further proofload test and re-examined.

3.6.19 The number of connecting common links whichmay be used to replace defective links is not to exceed threein any 100 m length of chain. The number and type of joiningshackles which may be used are to be subject to the writtenagreement of the end user.

3.6.20 If a link breaks during proof load testing, a sampleconsisting of three common links is to be taken from eachside of the broken link and subjected to a breaking test asdetailed in 3.6.21 and 3.6.22. If either of these samples fails,the proof loaded length of cable is not to be accepted. A thorough examination of all broken links is to be made todetermine the cause of failure and, after evaluation, LR willconsider the extent of cable which is to be rejected and alsothe possibility that similar factors to those which caused thefailure may also be present in other parts of the cable, or otherchain cables. The Surveyor is to be advised in advance of allexaminations, with reasonable notice being given.

3.6.21 In addition to the requirements of 3.6.2, three linksamples are to be selected by the Surveyors from thecompleted chain for breaking tests. The number of testsrequired is to be in accordance with Table 10.3.2. Extra linksare to be provided for the mechanical tests detailed in 3.6.25.All test links are to be made as part of the chain cable and areto be heat treated with it. These may be removed from thecable prior to heat treatment provided that each sample isheat treated with, and in the same manner as, the chain itrepresents prior to selection of the mechanical test specimens. They are to be properly identified with the lengthof chain they represent.




Fig. 10.3.2 Stud link chain cable common link tolerances

The internal link radii (R) and external radii should be uniform

Designation Description Nominal dimension Minus tolerance Plus toleranceof the link

a Link length 6d 0,15d 0,15d

b Link half length a*/2 0,10d 0,10d

c Link width 3,6d 0,09d 0,09d

e Stud angular misalignment 0 degrees 4 degrees 4 degrees

R Inner radius 0,65d 0 —

Symbols

d = nominal diameter of chaina* = actual link length

R

Crown

b

a

c




Tab

le 1

0.3.

1Te

st lo

ads

for

mo

ori

ng c

hain

cab

les

(con

tinue

d)

Nom

inal

diam

eter

dB

reak

test

load

Bre

ak te

stlo

adB

reak

test

load

Bre

ak te

stlo

adB

reak

test

load

Stu

d lin

kch

ain

Stu

dles

sch

ain

Stu

d lin

kch

ain

Stu

dles

sch

ain

Stu

d lin

kch

ain

Stu

dles

sch

ain

Stu

d lin

kch

ain

Stu

dles

sch

ain

Stu

d lin

kch

ain

Stu

dles

sch

ain

mm

kNkN

kNkN

kNkN

kNkN

kNkN

kNkN

kNkN

kN

50 52 54 56 58 60 62 64 66 68 70 73 76 78 81 84 87 90 92 95 97 100

102

105

107

111

114

117

120

122

124

127

130

132

137

1480

1594

1712

1834

1960

2089

2221

2357

2496

2639

2785

3010

3242

3400

3643

3893

4149

4412

4590

4862

5047

5328

5519

5809

6005

6404

6709

7018

7331

7542

7755

8078

8404

8623

9178

1480

1594

1712

1834

1960

2089

2221

2357

2496

2639

2785

3010

3242

3400

3643

3893

4149

4412

4590

4862

5047

5328

5519

5809

6005

6404

6709

7018

7331

7542

7755

8078

8404

8623

9178

2230

2402

2580

2764

2953

3147

3347

3551

3761

3976

4196

4535

4884

5123

5490

5866

6252

6647

6916

7326

7604

8028

8315

8753

9048

9650

1010

910

574

1104

711

365

1168

612

171

1266

312

993

1382

9

1800

1939

2083

2231

2383

2540

2701

2867

3036

3209

3387

3660

3942

4135

4431

4735

5046

5365

5582

5913

6138

6480

6712

7065

7304

7789

8159

8535

8916

9173

9432

9824

1022

110

488

1116

2

1740

1874

2013

2156

2304

2455

2611

2771

2935

3102

3274

3538

3811

3997

4283

4577

4878

5187

5396

5716

5933

6264

6488

6829

7060

7529

7887

8251

8619

8868

9118

9497

9880

1013

810

790

2490

2682

2881

3086

3297

3514

3737

3965

4200

4440

4685

5064

5454

5720

6130

6550

6981

7422

7722

8180

8490

8964

9285

9773

1010

3

1077

511

287

1180

712

334

1269

0

1304

813

591

1413

914

508

1544

1

2160

2327

2499

2677

2860

3048

3242

3440

3643

3851

4064

4392

4731

4962

5317

5682

6056

6439

6699

7096

7365

7776

8054

8478

8764

9347

9791

1024

210

700

1100

8

1131

911

789

1226

512

585

1339

5

1920

2068

2222

2380

2542

2710

2881

3058

3238

3423

3613

3904

4205

4411

4726

5051

5383

5723

5954

6307

6547

6912

7159

7536

7790

8308

8703

9104

9511

9785

1006

110

479

1090

311

187

1190

6

2740

2952

3170

3396

3628

3867

4112

4364

4621

4885

5156

5572

6001

6295

6745

7208

7682

8167

8497

9001

9343

9864

1021

710

754

1111

8

1185

612

420

1299

313

573

1396

4

1435

814

955

1555

915

965

1699

2

2400

2585

2777

2974

3178

3387

3602

3822

4048

4279

4516

4881

5257

5514

5908

6313

6729

7154

7443

7884

8184

8640

8949

9420

9738

1038

510

879

1138

011

889

1223

1

1257

613

099

1362

813

984

1488

3

2130

2295

2465

2640

2820

3006

3196

3392

3593

3798

4008

4331

4665

4893

5243

5603

5972

6349

6606

6997

7263

7668

7942

8360

8643

9217

9655

1010

010

551

1085

5

1116

111

626

1209

512

411

1320

9

3040

3275

3517

3768

4025

4290

4562

4841

5127

5420

5720

6182

6658

6984

7484

7997

8523

9062

9428

9987

1036

610

944

1133

611

932

1233

5

1315

413

780

1441

515

059

1549

3

1593

016

592

1726

217

713

1885

2

2510

2704

2904

3111

3323

3542

3767

3997

4233

4475

4723

5104

5498

5766

6179

6602

7037

7482

7784

8246

8559

9036

9359

9851

1018

4

1086

111

378

1190

212

434

1279

2

1315

313

700

1425

314

625

1556

5

2230

2402

2580

2764

2953

3147

3347

3551

3761

3976

4196

4535

4884

5123

5490

5866

6252

6647

6916

7326

7604

8028

8315

8753

9048

9650

1010

910

574

1104

711

365

1168

612

171

1266

312

993

1382

9

3200

3447

3703

3966

4237

4516

4802

5096

5397

5706

6021

6507

7009

7351

7877

8418

8971

9539

9924

1051

2

1091

111

520

1193

212

560

1298

4

1384

714

506

1517

415

852

1630

8

1676

817

466

1817

118

645

1984

4

Gra

de R

3G

rade

R3S

Gra

de R

4G

rade

R4S

Gra

de R

5

Pro

of te

st lo

adP

roof

test

load

Pro

of te

st lo

adP

roof

test

load

Pro

of te

st lo

ad




Tab

le 1

0.3.

1Te

st lo

ads

for

mo

ori

ng c

hain

cab

les

(con

clus

ion)

Nom

inal

diam

eter

dB

reak

test

load

Bre

ak te

stlo

adB

reak

test

load

Bre

ak te

stlo

adB

reak

test

load

Stu

d lin

kch

ain

Stu

dles

sch

ain

Stu

d lin

kch

ain

Stu

dles

sch

ain

Stu

d lin

kch

ain

Stu

dles

sch

ain

Stu

d lin

kch

ain

Stu

dles

sch

ain

Stu

d lin

kch

ain

Stu

dles

sch

ain

mm

kNkN

kNkN

kNkN

kNkN

kNkN

kNkN

kNkN

kN

142

147

152

157

162

167

172

177

182

187

192

197

202

207

210

9741

1031

110

887

1146

912

056

1264

713

240

1383

614

433

1502

9

1562

616

220

1681

317

401

1775

3

9741

1031

110

887

1146

912

056

1264

713

240

1383

614

433

1502

9

1562

616

220

1681

317

401

1775

3

1467

715

536

1640

517

282

1816

6

1905

619

950

2084

721

746

2264

6

2354

424

440

2533

226

220

2674

9

1184

712

540

1324

113

949

1466

3

1538

116

103

1682

717

553

1827

9

1900

419

727

2044

821

164

2159

1

1145

212

122

1280

013

484

1417

4

1486

915

566

1626

716

968

1767

0

1837

119

070

1976

620

459

2087

2

1638

817

347

1831

719

297

2028

4

2127

822

276

2327

824

282

2528

6

2628

927

290

2828

629

277

2986

8

1421

615

048

1589

016

739

1759

6

1845

819

324

2019

321

064

2193

5

2280

523

673

2453

725

397

2591

0

1263

713

376

1412

414

879

1564

1

1640

717

177

1794

918

723

1949

8

2027

121

043

2181

122

575

2303

1

1803

319

089

2015

621

234

2232

0

2341

424

513

2561

526

720

2782

5

2892

930

029

3112

632

216

3286

7

1579

616

720

1765

518

599

1955

1

2050

821

471

2243

723

404

2437

2

2533

926

303

2726

428

219

2878

8

1401

914

839

1566

916

507

1735

1

1820

119

055

1991

220

771

2163

0

2248

823

344

2419

625

044

2555

0

2000

821

179

2236

323

559

2476

4

2597

727

196

2842

029

645

3087

1

3209

633

317

3453

435

744

3646

5

1652

017

487

1846

419

452

2044

7

2144

822

455

2346

524

477

2548

9

2650

027

509

2851

329

512

3010

8

1467

715

536

1640

517

282

1816

6

1905

619

950

2084

721

746

2264

6

2354

424

440

2533

226

220

2674

9

2106

122

294

2354

024

799

2606

8

2734

528

628

2991

531

205

3249

6

3378

535

071

3635

137

625

3838

5

Gra

de R

3G

rade

R3S

Gra

de R

4G

rade

R4S

Gra

de R

5

Pro

of te

st lo

adP

roof

test

load

Pro

of te

st lo

adP

roof

test

load

Pro

of te

st lo

ad

Gra

de R

3P

roof

test

load

S

tud

link

chai

n 0,

0148

d2(4

4 –

0,08

d)S

tudl

ess

chai

n 0,

0148

d2(4

4 –

0,08

d)B

reak

test

load

0,

0223

d2(4

4 –

0,08

d)

Gra

de R

3SP

roof

test

load

S

tud

link

chai

n 0.

0180

d2(4

4 –

0,08

d)S

tudl

ess

chai

n 0,

0174

d2(4

4 –

0,08

d)B

reak

test

load

0,

0249

d2(4

4 –

0,08

d)

Gra

de R

4P

roof

test

load

S

tud

link

chai

n 0,

0216

d2(4

4 –

0,08

d)S

tudl

ess

chai

n 0,

0192

d2(4

4 –

0,08

d)B

reak

test

load

0,

0274

d2(4

4 –

0,08

d)

Gra

de R

4SP

roof

test

load

S

tud

link

chai

n 0,

0240

d2(4

4 –

0,08

d)S

tudl

ess

chai

n 0,

0213

d2(4

4 –

0,08

d)B

reak

test

load

0,

0304

d2(4

4 –

0,08

d)

Gra

de R

5P

roof

test

load

S

tud

link

chai

n 0,

0251

d2(4

4 –

0,08

d)S

tudl

ess

chai

n 0,

0223

d2(4

4 –

0,08

d)B

reak

test

load

0,

0320

d2(4

4 –

0,08

d)

3.7.2 Manufacture and heat treatment of the connectingcommon link is not to affect the strength of the adjoining links.The temperature reached by these links is nowhere to exceed250°C.

3.7.3 The steel bar used is to conform with the specifica-tion for the chain and approved by LR in accordance with Ch 3,9.

3.7.4 Details of the method of manufacture, includingheat treatment, are to be submitted for approval, togetherwith the results of a series of tests laid down by LR.

3.7.5 All links involved in the approval tests are to bedestroyed and are not to be used as part of a chain cable.

3.7.6 Every connecting common link included in a chaincable is to be subjected to the proof load appropriate to thegrade and size of chain in which it is incorporated as detailedin Table 10.3.1.

3.7.7 Every connecting common link is to be inspectedin accordance with 3.6.5 to 3.6.10.

3.7.8 A second identical link is to be made for mechanicaltests which are to be in accordance with 3.6.25. This test linkis also to be inspected in accordance with 3.7.7.

3.7.9 Each connecting common link is to be stamped onthe stud with the identification marks listed in 3.9.1 plus aunique number for the link. The adjoining links are also to bestamped on the studs.

3.8 Fittings for offshore mooring chain

3.8.1 Cable fittings are to be manufactured at anapproved works. Fittings include, but are not limited to, shackles, triplates, end shackles, swivels, and swivel shackles.

3.6.22 Breaking test specimens are to withstand the loadgiven in Table 10.3.1 for the appropriate grade and size ofcable for a period of 30 seconds. The specimen is consideredto have passed this test if it has shown no sign of fractureafter application of the required load.

3.6.23 If a breaking test specimen fails, two further specimens are to be cut from the same sampling length andboth are to be subjected to the breaking test load. If one ofthe re-test specimens fails the length is to be rejected. All thebroken links are to be subjected to an investigation into thecause of failure. LR will then decide which lengths of chaincan be accepted and on further action.

3.6.24 For large diameter cables where the required breaking load is greater than the capacity of the testingmachines, special consideration will be given to acceptanceof an alternative testing procedure.

3.6.25 One tensile and three sets of Charpy V-notchimpact test specimens are to be taken from links cut from theheat treated and proof loaded chain at intervals no greaterthan those indicated in Table 10.3.2 provided that every castis sampled. The tensile specimen and one set of impact specimens are to be taken from the side of the link oppositethe weld. One set of impact test specimens is to have thenotches positioned at the centre of the flash butt weld andthe third set is to be taken from the bend. All the specimensare to be taken from positions in accordance with Fig. 10.3.3.

3.6.26 The frequency of testing at the link bends may bereduced at the discretion of LR provided it can be verified thatthe required toughness is achieved consistently.

3.6.27 The results of the mechanical tests are to complywith the requirements of Table 10.3.3.

3.6.28 If the tensile test requirements are not achieved,two further specimens from the same sample are to betested. The related length of chain will be considered accept-able if both re-test specimens meet the requirements butfailure of either of the re-test specimens will result in rejectionof the sampling length of chain represented by the tests.

3.6.29 If the impact test requirements are not achieved, re-tests may be carried out in accordance with Ch 1,2.4.Failure to meet the re-test requirements will result in rejectionof the sampling length of chain represented by the tests.

3.6.30 The mass per unit length of stud link mooring cableis to comply with Table 10.3.4.

3.7 Connecting common links or substitute links

3.7.1 Single links to connect lengths of heat treated chaincable or to substitute for test links or defective links withoutthe necessity for re-heat treatment of the whole length ofcable are to be made by the chain manufacturer in accor-dance with an approved procedure. Separate approvals arerequired for each grade of chain cable and tests are to bemade on the maximum size of chain for which approval issought.




Nominal chain Maximumdiameter sampling interval

mm m (See Note)

Min. — 48 9149 — 60 11061 — 73 13174 — 85 15286 — 98 17599 — 111 198

112 — 124 222125 — 137 250138 — 149 274150 — 162 297163 — 175 322176 — 186 346187 — 199 370199 — 210 395

NOTEIf the sampling interval contains links made from more than one cast, extra break and mechanical tests are required so that tests are made on every cast.

Table 10.3.2 Frequency of break and mechanicaltests

3.8.2 The materials from which the fittings are made areto be manufactured at approved works, in accordance withthe appropriate requirements of Ch 4,1 or Ch 5,1, and 3.8.3to 3.8.6. Alternative arrangements may be agreed providedthat full details concerning the manufacturer are submitted toLR.

3.8.3 Steel used for fittings must be manufactured by anapproved process, and be killed and fine grain treated.

3.8.4 The austenite grain size of steel used for fittingsmust be 6 or finer as measured in accordance with ASTME112.

3.8.5 Steel used for forgings or castings for grades R4Sand R5 must be vacuum degassed.




Charpy V-notchimpact tests

Yield stressTensile strength

ElongationReduction

Grade N/mm2N/mm2 %

of area Test Average Average energy

minimum minimum% temperature energy flash weld

minimum ºC J J(See Note 3) minimum minimum

R3 410 690 minimum 17 50 0 60 50(See Note 1) (See Note 1) –20 40 30

(See Note 2)

R3S 490 770 minimum 15 50 0 65 53(See Note 1) (See Note 1) –20 45 33

(See Note 2)

R4 580 860 minimum 12 50 –20 50 36(See Note 1) (See Note 1)

R4S 700 960 12 50 –20 56 40(See Note 4) (See Note 1) (See Note 1)

R5 760 1000 12 50 –20 58 42(See Note 4) (See Note 1) (See Note 1)

NOTES1. The ratio of yield strength to tensile strength should not exceed 0,92.2. Testing may be carried out at either 0°C or –20°C.3. For cast fittings, the minimum values for reduction of area are to be 40% for Grades R3 and R3S and 35% for Grades R4, R4S and R5.4. The maximum hardness for Grade R4S is to be HB330, and for Grade R5 is to be HB340.

Table 10.3.3 Mechanical properties of chain cable materials

r/3

Specimen for notched bar impact test

r/3

Specimen for notched bar impact test

r/3

r = specimen radius

Tensilespecimen

Fig. 10.3.3 Sampling of chain links

Table 10.3.4 Mass per unit length of chain cable

Nominal chain diameterMass per unit length

(mm)0,0291d2

(kg/m)

50 7355 8860 10565 12370 14375 16480 18685 21090 23695 263100 291105 321110 352115 385120 419125 455130 492135 530140 570145 612150 655155 699160 745165 792170 841175 891180 943185 996190 1051195 1107200 1164205 1223210 1283

3.8.6 For steel used for forgings or castings for gradesR4S and R5 the following tests are to be carried out on eachheat:(a) Assessment and quantification of the level of non-metallic

micro inclusions. These must be acceptable for the finalproduct.

(b) Macro etching on representative sample, in accordancewith ASTM E381 or equivalent, this must be free fromany injurious segregation or porosity.

(c) Jominy hardenability tests in accordance with ASTMA255 or equivalent.

The results of these tests are to be supplied by the steelmanufacturer, and the results are to be included in the finalaccessory documentation.

3.8.7 Fittings for chain are to be heat treated in accor-dance with procedures that have been approved by LR.

3.8.8 All fittings are to be manufactured to a manufacturingspecification approved by LR, and provision is to be made fortensile and impact test specimens. The test samples are tobe subjected to heat treatment with the fittings they represent.The mechanical test requirements are the same as those forthe relevant grade of chain cable, see Table 10.3.3.

3.8.9 For fittings for mooring chain, a batch is defined asfittings from the same steel-making heat that have been heattreated together in the same furnace.

3.8.10 Mechanical tests for fittings are to be taken from fullsize fittings that have been heat treated with the productionbatch they represent, and the tests are to be taken after thefitting has been proof load tested. It is not permitted to useseparate representative coupons unless approved by LR inaccordance with 3.8.14.

3.8.11 Forged shackle bodies and forged Kenter shacklesare to have a set of three Charpy impact tests and a tensiletest taken from the crown of the shackle. For smaller diameter shackles, where the geometry does not allow for thetensile test to be taken from the crown, this may be takenfrom the straight portion from the locations specified in Fig. 10.3.4, with the Charpy impact test specimens on theoutside radius.

3.8.12 The test pieces for cast shackle bodies and castKenter shackles can be taken from the straight portion of thefitting from the locations shown in Fig. 10.3.4.

3.8.13 For fittings with complex geometries the locationsof test pieces taken are to be approved by LR.

3.8.14 Where fittings are produced in small batches (lessthan 5) alternative testing may be approved; a proposal mustbe submitted in a written procedure for consideration.

3.8.15 Mechanical tests of pins are to be taken as shownin Fig. 10.3.5 from the mid length of a sacrificial pin of thesame diameter as the final pin. For oval pins, the diametertaken is to represent the smaller dimension. Mechanical testsmay be taken from an extended pin of the same diameter asthe final pin that incorporates a test prolongation and a heattreatment buffer prolongation, where equivalence with midlength test values have been established. The length of thebuffer is to be at least equal to 1 pin diameter which isremoved after the heat treatment cycle is finished. The testcoupon can then be removed from the pin. The buffer and testare to come from the same end of the pin, as shown in Fig. 10.3.5.

3.8.16 Manufacturers intending to supply accessories inthe machined condition (e.g. Kenter type shackles) are tosubmit detailed drawings for approval by LR.




r/3

r/3

Specimen for notched barimpact test

Testspecimen

r = specimen radius

Fig. 10.3.4Sampling of steel bars, forgings and castings

TestPin Buffer

Fig. 10.3.5Buffer and test piece location for pins

3.8.17 All chain cable accessories, including spares, are tobe subjected to the proof loads appropriate to the grade andsize of cable for which they are intended, see Table 10.3.1.Prior to this test, the accessories are to be shot or sandblasted to ensure that their surfaces are free from scale, paintor any other coating which could interfere with any subse-quent inspection.

3.8.18 The appropriate breaking load as required by Table 10.3.1 is to be applied to at least one item out of everybatch of up to 25, and this item is to be destroyed and notused as part of an outfit.

3.8.19 If the sample fails to withstand the breaking loadwithout fracture, or in the event of failure of any other test,then the entire batch is to be rejected unless the cause of failure has been determined and it can be demonstrated thatthe condition causing failure is not present in any of the otheraccessories in the batch. If this can be demonstrated thentwo more samples from the same batch may be tested. Ifeither of these samples fails, the batch is to be rejected.

3.8.20 For very large fittings where the required breakingload is greater than the capacity of the testing machine andfor individually produced accessories or accessoriesproduced in small batches, proposals for an alternativemethod of testing will be given special consideration. Allproposals for alternative testing methods are to be detailedin writing and submitted.

3.8.21 At least one accessory from each batch is to bechecked dimensionally after proof load testing. The manufac-turer is to provide a statement that the dimensions complywith the specified requirements.

3.8.22 The following tolerances apply of the unmachineddimensions of all fittings;(a) nominal diameter plus 5 per cent, minus 0 per cent; and(b) other dimensions plus or minus 2,5 per cent.

3.8.23 All accessories are to be subjected to close visualexamination after proof load testing, particular attention beingpaid to machined surfaces and highly stressed regions. Allaccessories are also to be examined by magnetic particle or dyepenetrant inspection and ultrasonic testing. All NDE is to becarried out in accordance with 3.6.9 and 3.6.10. The manufac-turer is to provide a statement that the non-destructiveexamination has been carried out with satisfactory results; thisstatement is to include reference to the techniques used and theoperator’s qualifications.

3.8.24 All testing is to be carried out to the satisfaction andin the presence of the Surveyor.

3.8.25 Fittings of increased dimensions or higher gradematerial may be used subject to approval by LR.

3.8.26 Where fittings with increased dimensions, or fittingsof a higher material grade are included in an outfit:(a) each item must be successfully tested at the required

breaking load for the chain cable for which it is intended;and

(b) items of increased dimensions are so designed that theirbreaking strength is not less than 1,4 times the Ruleminimum breaking load for the chain cable for which theyare intended, and this has been verified by proceduretests.

3.9 Identification

3.9.1 Each length of chain is to be permanently markedwith the following:(a) LR and abbreviated name of LR’s local office issuing the

certificate.(b) Certificate number (this may be abbreviated provided it is

stated in the certificate).(c) Grade and proof load of chain.

3.9.2 The chain is to be marked as follows:(a) at each end (the marking should identify the leading and

tail end of each chain),(b) at intervals not exceeding 100 m,(c) on all connecting common links or shackles and the

immediately adjacent links,(d) on the first and last common link of each individual heat

used in the continuous length.

3.9.3 All identification marks are to be made on the studsand are to be permanent and legible throughout the expectedservice life of the chain.

3.10 Documentation

3.10.1 A complete Chain Inspection and Testing Report,in booklet form, is to be provided by the chain manufacturerfor each continuous chain length, and for each order for chainand fittings. It is to include all dimensional checks, test andinspection reports, non-destructive test reports, processrecords, as well as any non-conformity, together with correc-tive action and repair work.

3.10.2 All documents, including reports and appendices,are to contain a reference to the relevant certificate number.

3.10.3 The chain manufacturer is responsible for storing allthe documentation in a safe and retrievable manner for aperiod of at least 10 years.

3.11 Certification

3.11.1 An LR certificate is to be issued for each continuoussingle length of chain, and each type of fitting, see Ch 1,3.1.




3.11.2 Each test certificate is to include the followingparticulars:(a) Purchaser’s name and order number.(b) Description and dimensions.(c) Grade of chain cable.(d) Identification mark which will enable the full history of the

chain to be traced.(e) Chemical composition.(f) Details of heat treatment.(g) Mechanical test results.(h) Breaking test load.(j) Proof load.(k) The number and locations of all connecting common

links and all marked links.

■ Section 4Studless mooring chain cables

4.1 Scope

4.1.1 Provision is made in this Section for five grades, R3,R3S, R4, R4S and R5 of studless flash butt welded chaincable intended for long term mooring applications.

4.1.2 The chain is generally expected to be deployed onlyonce for a pre-determined service life.

4.1.3 Each studless chain link design will require to beapproved by LR. The plan submitted for this approval is toinclude the minimum proof and breaking test loads, and thechain mass calculations.

4.2 Manufacture

4.2.1 All the requirements of 3.2, with the exception ofthat relating to studs, apply to the manufacture of studlessmooring chain cables.

4.3 Shape and dimensions of links

4.3.1 The shape and dimensions of the links are to be inaccordance with the approved design.


4.4.1 The dimensional tolerances of studless links are tobe in accordance with the requirements of 3.3.1 to 3.3.7.

4.4.2 The tolerances for common links are to bemeasured in accordance with Fig. 10.4.1.

4.5 Heat treatment

4.5.1 Heat treatment of the chain is to be in accordancewith the requirements of 3.5.

4.6 Testing of completed chain

4.6.1 All chain cables are to be tested in the presence ofa Surveyor, at a proving establishment recognised by LR. Alist of recognised proving establishments is published by LR.In addition to the requirements stated in this Chapter, attention must be given to any relevant statutory requirementsof the National Authority of the country in which the ship is tobe registered.




Fig. 10.4.1 Studless chain cable common link tolerances

The internal link radii (R) and external radii should be uniform

Designation Description Nominal dimension Minus tolerance Plus toleranceof the link

a Link length 6d 0,15d 0,15d

b Link width 3,35d 0,09d 0,09d

R Inner radius 0,60d 0 —

Symbols

d = nominal diameter of chain

NOTEOther dimensional ratios are subject to special approval.

b

a

4.6.2 The entire length of chain cable is to be subjectedto a proof load test in an approved testing machine and is towithstand the load given in Table 10.3.1 for the appropriategrade and diameter of the chain, see also 4.1.3.

4.6.3 Inspection after proof load testing is to be in accordance with the requirements given in 3.6.3 to 3.6.20,excluding that related to checking of studs in 3.6.5.

4.6.4 In addition to the inspection of the flash butt weldedareas as required in 3.6.6, the surfaces of the bends of at least10 per cent of the links are to be examined by magnetic particle inspection and are to be free from cracks or otherdefects.

4.6.5 If stretching of links is required in order to maintaindimensional tolerances, the load applied is not to exceed theproof load by more than 10 per cent, and only random lengthsof the chain need to be stretched.

4.6.6 Breaking load tests are to be carried out in accor-dance with 3.6.21 to 3.6.23 and Tables 10.3.1 and 10.3.2.

4.6.7 Alternative procedures to breaking load testing (see3.6.24) are not permissible unless prior agreement is given byLR after special consideration.

4.6.8 Mechanical testing is to be carried out in accordance with 3.6.25 to 3.6.30 and Table 3.3.4.

4.6.9 The weight of the chain cable is to be in accor-dance with the approved plan.

4.7 Connecting or substitute links

4.7.1 Connecting links and substitute links are to be inaccordance with the requirements of 3.7.

4.8 Fittings

4.8.1 Fittings for studless chain are to comply with therequirements of 3.8.

4.9 Identification

4.9.1 All chain and each fitting is to be identified in accor-dance with 3.9.1 and 3.9.2.

4.9.2 Identification marks are to be made on the outsideof the straight part of the link, opposite the flash butt weld.

4.10 Certification

4.10.1 Certificates are to be issued in accordance with3.11.

4.11 Documentation

4.11.1 Documentation in accordance with 3.11 is to beprovided by the manufacturer.

■ Section 5Short link chain cables

5.1 Scope

5.1.1 This Section gives the requirements for electricallywelded steel short link chain cable for marine use but excluding those applications covered by the Code for LiftingAppliances in a Marine Environment.

5.1.2 Provision is made for grade M(4), as defined in ISO 1834.

5.2 Manufacture

5.2.1 Short link chain cables are to be manufactured atworks approved by LR. A list of approved manufacturers forshort link chain cable is published separately by LR.

5.2.2 The chain is to be supplied in either the normalisedor quenched and tempered condition. Heat treatment is to becarried out prior to proof and breaking load testing.

5.2.3 The chain may be galvanised using a hot dippingprocess provided that this is carried out prior to proof andbreaking load testing. If galvanised, it is recommended thatthe thickness of the zinc coating be not less than 70 microns.

5.2.4 Unless otherwise agreed, the finished chain is to befree from coatings other than zinc.

5.3 Bar material

5.3.1 Bars for the manufacture of short link chain cableare to be made and tested in accordance with the appropriaterequirements of Ch 3,1 and to the requirements of anInternational or acceptable National Standard.

5.3.2 The bars are to be made at a works approved by LR.

5.3.3 The steel is to be fully killed and fine grain treated.

5.3.4 The steel is to have mechanical properties whichwill allow the chain to meet the mechanical test requirementsof 5.4.7 and Table 10.5.1.




5.4 Testing and inspection of chain cables

5.4.1 All chain cable of 12,5 mm diameter and above,and all steering chains irrespective of diameter, are to betested in the presence of a Surveyor at a proving establish-ment recognised by LR. A list of recognised provingestablishments is published by LR. In addition to the require-ments stated in this Chapter, attention is to be given to anyrelevant statutory requirements of the National Authority of thecountry in which the ship or other marine structure is to beregistered.

5.4.2 For chain of diameter less than 12,5 mm, other thansteering chains, the manufacturer’s tests will be acceptable.

5.4.3 After completion of all manufacturing processes,including heat treatment and galvanising, the whole of thechain is to be subjected to the appropriate proof load specified in Table 10.5.1.

5.4.4 The whole of the chain is to be inspected after theproof load test and is to be free from significant defects.

5.4.5 At least one sample, consisting of seven or morelinks, is to be selected by the Surveyor from each 200 m orless of chain for breaking load tests. Two additional links maybe required for engagement in the jaws of the testingmachine. These extra links are not to be taken into accountin determining the total elongation, see 5.4.7.

5.4.6 The breaking load is to comply with the appropri-ate requirements of Table 10.5.1.

5.4.7 The total elongation of the breaking load sample atfracture, expressed as a percentage of the original insidelength of the sample after proof loading, is to be not less than20 per cent.


5.5.1 The form and proportions of links are to be in accordance with Fig. 10.5.1.

5.5.2 Manufacturing tolerances are to be within thefollowing limits:

Nominal diameter, dn ± 5%Pitch of chain, p1 ± 3%Length measured over 11 links, l ± 2%Inside width, w1 1,35dn minimumOutside width, w 3,6dn maximum

The tolerances are to apply after galvanising. All measure-ments are to be taken after proof testing.




Table 10.5.1 Mechanical test requirements for shortlink chain cables

Grade M(4)Chain

diameterProof load

Breaking load mm

kNminimum

kN

5 7,9 15,86,3 12,5 257,1 15,9 31,88 20,2 40,49 25,5 51

10 29,5 6311,2 31,5 7912,5 49,1 98,214 63 12616 81 16218 102 20420 126 25222,4 158 31625 197 39428 247 49432 322 64436 408 81640 503 100645 637 1274

l

A

A

e

e

p

w3 w4

Type 1

φdw

φdwA–A

B

B

e

e

p

w3 w4

Type 2

φdw

φdwB–B

G

l = multiple pitch lengthp = pitch (internal link length)dn = measured diameter of the material, except at the welddw = measured diameter of the material at the weld (Type 1) or weld dimension perpendicular to the plane of the link (Type 2)G = dimension in other planes as per individual chain specification (Type 2)e = length affected by welding, on either side of the centre linkw1 = internal link width away from the weldw2 = external link width away from the weldw3 = external link width over the weldw4 = internal link width at the weld

Fig. 10.5.1 Form and proportions of links

5.6 Identification

5.6.1 All lengths of cable are to be stamped with thefollowing identification marks:(a) Inspector’s mark and date.(b) Reference mark or number of certificate.(c) Manufacturer’s mark or name.(d) Chain cable quality mark, M, is to be stamped on at least

each twentieth link or at intervals of one metre,whichever is the lesser distance.

5.6.2 Where the inspection is performed under LR’ssupervision, the inspector’s mark and date are to be replacedby LR and the abbreviated name of LR’s local office issuingthe certificate.

5.7 Certification

5.7.1 The manufacturer is to supply the Surveyor with acertificate stating compliance with an appropriate ISO standard, and also, in the event of the requirements of 5.4being undertaken other than in the presence of the Surveyor,stating that the test and inspection requirements have beencomplied with at a recognised proving establishment.

5.7.2 Each test certificate is to include the followingparticulars:(a) the quality and description of chain,(b) identification mark,(c) nominal size of chain,(d) proof load,(e) breaking load,(f) total elongation at fracture,(g) where appropriate, the name of the proving establishment.

■ Section 6Steel wire ropes

6.1 Scope

6.1.1 Provision is made in this Section for the requirementsfor the manufacture, testing and certification of steel wire ropesintended to be used for general marine purposes, as well aspermanent anchoring, mooring and marine lifting applications.

6.2 General requirements

6.2.1 For general marine purposes, such as stream wires,towlines and ship mooring lines, the construction is to be inaccordance with Table 10.6.1. The construction, diameter andstrength of steel wire ropes for permanent offshore applica-tions, such as mooring, anchoring and lifting, are covered byother LR Rules. Alternative applications of wire ropes may beaccepted, subject to special consideration.

6.2.2 The manufacturer’s plant and method of productionare to be approved by LR. A list of approved manufacturers ofsteel wire ropes is published annually in the List of ApprovedManufacturers of Materials.

6.2.3 For shaped wire, for example, for large diameterropes for permanent mooring, where there are no establishedStandards, the manufacturer is to provide evidence by way oftest reports that specifications have been developed andagreed with the purchaser and LR for the purposes intended.

6.3 Steel wire for ropes

6.3.1 Steel wire is to be of homogeneous quality, uniformstrength and free of defects likely to impair the manufactureand performance of the rope.

6.3.2 For all ropes, the specified minimum tensile strengthof the wire is to be 1420, 1570, 1770 or 1960 N/mm2. Thespecified minimum tensile strength of the wire is the designated grade for the rope, unless otherwise defined bythe purchaser’s specification. The actual tensile strength ofthe wire is not to exceed 120 per cent of the specified minimum tensile strength.




Construction of ropePurpose Construction of strands

Strands Wires Core

Stream wires, towlines and 6 24 Fibre 15 over 9 over fibre coremooring lines 6 37 Fibre 18 over 12 over 6 over 1

6 26 Fibre 10 over (5 + 5) over 5 over 16 31 Fibre 12 over (6 + 6) over 6 over 16 36 Fibre 14 over (7 + 7) over 7 over 16 41 Fibre 16 over (8 + 8) over 8 over 16 30 Fibre 18 over 12 over fibre core

Towlines and mooring 6 31 7 x 7 wire rope 12 over (6 + 6) over 6 over 1lines used in association 6 36 7 x 7 wire rope 14 over (7 + 7) over 7 over 1with mooring winches 6 41 7 x 7 wire rope 16 over (8 + 8) over 8 over 1

Table 10.6.1 Recommended rope construction

6.3.3 For new rope construction, the manufacturer is tocarry out prototype testing suitable for the application of therope and this is to include tests on wire used for the construction.

6.3.4 Tensile and torsion tests, coating, and adhesion(wrap) tests are to be carried out on wire used for the manufacture of rope.

6.3.5 At least 10 per cent of the spools used for themanufacture of the strand are to be tested. The manufactureris to demonstrate that tests have been carried out on at leastone wire intended for each of the outer and inner strands, andfor each diameter and grade used.

6.3.6 The heat number, wire diameter and strength ofwire used for a particular construction are to be recorded bythe manufacturer.

6.3.7 Torsion tests are to be carried out on the wire bycausing one or both of the securing vices to be revolved untilfracture occurs (a tensile load not exceeding two per cent ofthe breaking load of the wire may be applied to keep the wirestretched).

6.3.8 The uncoated wire is to withstand, without fracture,the number of complete twists given for Grades 1 or 3 in Table 10.6.2.

6.3.9 The galvanised wire is to withstand, without fracture,the number of complete twists given in the specification, asagreed with the purchaser and LR. In the absence of a suitablespecification, the results are to comply with Table 10.6.2.

6.3.10 Hot dipped galvanised steel wire is to be used forthe manufacture of ropes for marine applications. Dependingupon the application, the coating may comply with any of thegrades in Table 10.6.3. Grades 1 and 2 are heavy coatings.Grade 3 is the minimum coating weight where the galvanisingis carried out prior to final wire drawing. Uncoated wire maybe considered for approved applications.

6.3.11 The mass per unit area of the zinc coating is to bedetermined in accordance with a recognised National orInternational Standard.

6.3.12 Zinc coating tests are to be carried out for eachdesignated grade of wire. The manufacturer is to demonstratethat the coatings are continuous and uniform and suitable forthe intended purpose.

6.3.13 Unless otherwise specified by the purchaser, zinccoating tests are to be carried out on the wire prior to stranding.

6.3.14 The adhesion of the coating is to be tested by wrapping the wire round a cylindrical mandrel for 10 completeturns. The ratio between the diameter of the mandrel and thatof the wire is to be as in Table 10.6.4. After wrapping on theappropriate mandrel, the zinc coating is to have neither flakednor cracked to such an extent that any zinc can be removedby rubbing with a cloth.

6.4 Tests on completed ropes

6.4.1 Every length of wire rope is to be subjected to abreaking strength test.

6.4.2 A sample of sufficient length is to be provided forthe breaking load test. The rope ends are to be enclosed in asuitable socket. Testing is to be carried out in accordance witha recognised National or International Standard.




Diameter of coated Maximum ratio ofCoating wire mandrel to wire

mm diameter

Grade 1 and 2 <1,5 4≥1,5 6

Grade 3 <1,5 2≥1,5 3

Table 10.6.4 Wrap test for adhesion of coating

Diameter of Zinc coating, minimum g/m2

coated wiremm Grade1 Grade 2 Grade 3

≥0,20 <0,25 — 30 20≥0,25 <0,33 — 45 30≥0,33 <0,40 — 60 30≥0,40 <0,50 60 75 40≥0,50 <0,60 70 90 50≥0,60 <0,80 85 110 60≥0,80 <1,00 95 130 70≥1,00 <1,20 110 150 80≥1,20 <1,50 120 165 90≥1,50 <1,90 130 180 100≥1,90 <2,50 — 205 110≥2,50 <3,20 — 230 125≥3,20 <4,00 — 250 135

Table 10.6.3 Zinc coating

Minimum number of twists

Diameter Grade 2 Grade 1 or 3coated wire

mm Minimum strength Minimum strengthN/mm2 N/mm2

1570 1770 1420 1570 1770 1960

<1,3 19 18 29 26 23 23

≥1,3 <2,3 18 17 26 24 21 21

≥2,3 <3,0 16 14 24 22 — 19

≥3,0 <4,0 12 10 20 18 — 17

≥4,0 <4,6 — — 18 16 — —

≥4,6 <5,0 — — 16 14 — —

≥5,0 <6,0 — — 14 11 — —

Table 10.6.2 Torsion test

NOTEThe minimum test length is 100d or 300 mm, where d is the wirediameter.

6.4.3 The rope may be subject to cyclic loading forbedding purposes prior to testing. The rope is to be tested ata suitable strain rate in accordance with a recognised Nationalor International Standard.

6.4.4 The load is to be applied until one wire break iswitnessed or 130 per cent of the minimum breaking load isrecorded. The maximum recorded load is to be reported bythe manufacturer.

6.4.5 Tests in which a breakage occurs adjacent to andas a result of damage from the grips are to be rejected, if theapplied load is less than the specified minimum requirement.The rope is to be retested to withstand the agreed minimumbreaking load.

6.4.6 With the exception of offshore mooring ropes,consideration may be given to determining the breaking loadby summation or aggregating actual test results on individualwires, if facilities are not available for undertaking a breakingtest on a production basis. A suitable spin factor or lay-updeduction allowance in accordance with a recognisedNational or International Standard for the applicable ropediameter, designated grade and construction is to be applied.

6.4.7 Where spin factors or lay-up deduction allowancesare proposed by the manufacturer, a report on suitable cyclicload testing of prototype ropes of the same construction,strength and diameter is to be approved by LR. In addition,the manufacturer is to show that a satisfactory breaking loadtest has been carried out in the previous two years, andwitnessed by LR for the same rope construction, diameterand designated grade.

6.4.8 LR may give special consideration to spin factorsor lay deductions based on data extrapolated from smaller diameter ropes of the same construction, provided that theseropes have been tested in accordance with 6.4.7.

6.4.9 All data arising from smaller diameter ropes for theextrapolation in 6.4.8 are to have been derived from testscarried out within two years of the manufacture of the largerdiameter rope.

6.4.10 The finished rope is to have no more than one wireconnecting weld in any length of 18d, where d is the diameterof the rope.

6.5 Inspection

6.5.1 A report on dimensional and visual examination isto be presented to the Surveyor by the manufacturer. Thedimensions and discard criteria are to comply with an agreedNational or International Standard.

6.6 Identification

6.6.1 All completed ropes are to be identified withattached labels detailing the rope type, diameter and length.

6.7 Certification

6.7.1 A manufacturer’s certificate, in accordance withCh1,3.1.3(c), is to be issued. The certificate is to be validatedby the manufacturer’s representative, who is to be indepen-dent of the production process and LR.

6.7.2 Each test certificate is to contain the followingparticulars:• Purchaser’s name and order number.• Details of the rope construction.• Core material.• Grade of zinc coating.• Mechanical test results.• Adhesion test results.• Dimensions.• Method of breaking load testing.• Breaking load.

■ Section 7Fibre ropes

7.1 Manufacture

7.1.1 Fibre ropes intended as mooring lines may bemade of coir, hemp, manila or sisal, or may be composed ofsynthetic (man-made) fibres. They may be three-strand(hawser laid), four-strand (shroud laid) or nine-strand (cablelaid), but other constructions will be specially considered.

7.1.2 Each length of rope is to be manufactured from suitable material of good and consistent quality. Rope materials should, in general, comply with a recognisedNational Standard.

7.1.3 Synthetic fibre ropes are to be suitable for thepurpose intended and should comply with a recognised standard.

7.1.4 Weighting and loading matter is not to be added,and any lubricant is to be kept to a minimum. Any rot-proofingor water repellancy treatment is not to be deleterious to thefibre nor is it to add to the weight or reduce the strength ofthe rope.

7.2 Tests of completed ropes

7.2.1 The breaking load is to be determined by testing todestruction a sample cut from the completed rope.

7.2.2 The minimum test length and the initial test load areto be as given in Table 10.7.1. After application of the initialload, the diameter and evenness of lay up of the sample are tobe checked. The sample is then to be uniformly strained atthe rate given in Table 10.7.1 until it breaks.

7.2.3 The actual breaking load is to be not less than thatgiven in an appropriate National Standard.




7.2.4 If the sample is held by grips and the break occurswithin 150 mm of the grips, the test may be repeated, but notmore than two tests may be made on any one coil.

7.2.5 Where difficulty is experienced in testing a sampleof a completed synthetic fibre rope, LR will consider alternativemethods of testing.

7.3 Identification

7.3.1 Each coil of rope is to be identified with an attachedlabel detailing the material, construction, diameter and length.

7.4 Certification

7.4.1 A manufacturer’s certificate, in accordance withCh1,3.1.3(c), is to be issued. The certificate is to be validatedby the manufacturer’s representative, who is to be indepen-dent of the production process and LR.

7.4.2 Each test certificate is to include the followingparticulars:• Manufacturer’s name.• Purchaser’s name and order number.• Rope type.• Dimensions.• Test length.• Rate of straining.• Breaking load.




Test length Initial loadRate of straining

Material mm %mm/min

minimum (see Note)

Natural fibre 1800 2 150 ± 50

Synthetic fibre 900 1 100 max.

NOTEPercentage of specified minimum breaking load.

Table 10.7.1 Breaking load test

Section

1 General

2 Mechanical testing procedures

3 Electrodes for manual and gravity welding

4 Wire-flux combinations for submerged-arcautomatic welding

5 Wires and wire-gas combinations for manual,semi-automatic and automatic welding

6 Consumables for use in electro-slag and electro-gas welding

7 Consumables for use in one-side welding withtemporary backing materials

8 Consumables for welding austenitic and duplexstainless steels

9 Consumables for welding aluminium alloys

■ Section 1General

1.1 Scope

1.1.1 Provision is made in this Chapter for the approvalby Lloyd’s Register (hereinafter referred to as ‘LR’) of electrodes, wires, fluxes and other consumables intended foruse in the welding of the following types of materials:(a) Steel of various grades as represented by Grade A

through to Grade FH69, see Sections 3 to 7.(b) A wide range of low-temperature service steels, see

Sections 3 to 7.(c) Stainless steels including nitrogen strengthened grades

and some of the duplex varieties, see Section 8.(d) Aluminium alloys, see Section 9.

1.1.2 For this purpose, welding, consumables are categorised and subject to the special requirements of different Sections of this Chapter.(a) Covered electrodes for manual welding and gravity

welding.(b) Combinations of wire and flux for automatic submerged-

arc welding.(c) Combinations of wire and gas for gas metal-arc welding

and wires for self-shielding welding.(d) Combinations for electro-slag and electro-gas welding.(e) Combinations with temporary backing materials for

one-side welding.(f) Consumables for welding austenitic and duplex stainless

steels.(g) Combinations for welding aluminium.

1.2 Grading

1.2.1 Consumables for welding structural steels aregraded into ten strength levels, and each of these is furthersubdivided into several levels in respect of notch toughness.The five basic levels of toughness are indicated by a number(1 to 5). Normal tensile strength is indicated by ‘N’. Highertensile strength is indicated by ‘Y’, and if the yield strength ishigher than 375 N/mm2 the Y is followed by a number (40 to 69), as shown in Table 11.1.1.

1.2.2 In addition to the grade, consumables are also allocated a suffix indicating the welding technique used.These are defined in the context of the following Sections ofthis Chapter.

1.2.3 Consumables for structural and low temperatureservice steels may be controlled low hydrogen and approvedas such. Grade marking H15, H10 or H5 will be applied, asappropriate.

1.2.4 For joining higher strength steels, approval grantedfor 1Y consumables will be limited to maximum material thickness of 25 mm.

1.2.5 Test assemblies are not to be subjected to any heattreatment, except in those higher strength grades where it isconsidered necessary to use the welded joint in the stressrelieved (tempered) condition. In those cases, the code ‘sr’will be added to the approval grade.

1.2.6 Further details of grading are given in subsequentSections of this Chapter.

1.3 Manufacture

1.3.1 The manufacturer’s plant and method of productionof welding consumables are to be such as to ensure reasonable uniformity in manufacture.

1.4 Approval procedures

1.4.1 Welding consumables will be approved subject toa satisfactory inspection of the works by the Surveyor forcompliance with the test requirements detailed in subsequentSections in this Chapter.

1.4.2 The test assemblies are to be prepared under thesupervision of the Surveyor, and using samples selected byhim. All tests are to be carried out in his presence.

1.4.3 For Charpy V-notch tests, a set of three test specimens is to be prepared and the average energy value isto comply with the requirements of subsequent Sections inthis Chapter. One individual value may be less than therequired average value provided that it is not less than 70 percent of this value.

1.4.4 Where chemical analysis is required for approval,the results of the analysis are not to exceed the limit valuesspecified in the standards or by the manufacturer, thenarrower tolerances being applicable in each case.


Approval of Welding Consumables Chapter 11Section 1


Consumable Suitable for steel gradesgrade (see Notes)

1. Ship Grade Steels (Ch 3,2 and Ch 3,3)

1N A AH27S — —2N B, D DH27S — —3N E EH27S — —

1Y A AH27S AH32 AH362Y B, D DH27S DH32 DH363Y E EH27S EH32 EH364Y — FH27S FH32 FH36

2Y40 AH32 AH36 AH40 —2Y40 DH32 DH36 DH40 —3Y40 EH32 EH36 EH40 —4Y40 FH32 FH36 FH40 —5Y40 FH32 FH36 FH40 —

3Y47 — — EH40 EH47

2. High Strength Steels (Ch 3,10) see Note 3

3Y42 AH36 AH40 AH42 —3Y42 DH36 DH40 DH42 —4Y42 EH36 EH40 EH42 —5Y42 FH36 FH40 FH42 —



3Y55 AH50 AH55 — —3Y55 DH50 DH55 — —4Y55 EH50 EH55 — —5Y55 FH50 FH55 — —



3. Ferritic Low Temperature Service Steels (Ch 3,6)

11/2 Ni 11/2 Ni — — —31/2 Ni 31/2 Ni — — —5 Ni 5 Ni — — —9 Ni 9 Ni — — —

NOTES1. Steel grades shown in bold italic type include the equivalent

(LT-xxxx) low temperature service grades referenced in Ch 3,6.2. The Table applies to the multi-run welding techniques (i.e. m,

S, M).3. Approval of consumables intended for welding high strength

steels in Ch 3,10 also includes the standard ship steel gradesas shown in bold italic type and equivalent low temperatureservice steel grades referenced in Ch 3,6.

Table 11.1.1 Welding consumable gradesappropriate to structural and lowtemperature service steel grades

1.4.5 LR may require, in any particular case, such additional tests or requirements as may be necessary.

1.4.6 A List of Approved Welding Consumables ispublished by LR.

1.4.7 LR is to be notified of any alteration proposed to bemade in the process of manufacture subsequent to approval.Sufficient detail is to be provided to determine the need forfurther testing to maintain the approval.

1.4.8 Consideration will be given to alternative proceduresfor approval in the case of manufacturers producing consumables under the control of another manufacturer orplant already having approval of one or more products.

1.5 Annual inspection and tests

1.5.1 All establishments where approved weldingconsumables are manufactured, and the associated qualitycontrol procedures, are to be subjected to annual inspection.On these occasions, samples of the approved consumablesare to be selected by the Surveyor and subjected to the testsdetailed in subsequent Sections in this Chapter. These are tobe completed and reported before the end of the one yearperiod beginning at the initial approval date, and repeatedannually so as to provide at least an average of one annualtest per year.

1.6 Changes in grading

1.6.1 Changes in grading of welding consumables will beconsidered only at the manufacturer’s request, preferably atthe time of annual testing. For upgrading in connection withimpact properties, and uprating in connection with tensileproperties, tests from butt weld assemblies will be required inaddition to the normal annual approval tests. For upgradingin connection with hydrogen testing, specific tests will berequired in accordance with ISO 3690. Downgrading anddownrating may be imposed by LR where tests and re-testsfail to meet the requirements of this Chapter.

1.7 Manufacturers’ Quality Assurance Systems

1.7.1 As an alternative to 1.5, manufacturers may seekmaintenance of approval based on acceptance by LR of their‘in house’ quality assurance system, and by regular audit ofthat system carried out in accordance with proceduresapproved by LR.

1.8 Certification

1.8.1 Each carton or package of approved consumablesis to contain a certificate from the manufacturer, generally inaccordance with the following: ‘The <insert name of manufacturer> company certifies that the composition andquality of these consumables conform with those of theconsumables used in making the test pieces submitted to andapproved by the approval bodies nominated on the label ofthis package.’



LLOYD’S REGISTER2

3.1.5 Electrodes approved for normal and higher strengthlevels up to and including ‘Y’ are also considered suitable forwelding steels in the three strength levels below that for whichthey have been approved.

3.1.6 Electrodes approved for strength levels Y40 to Y50,but excluding Y47 are also considered suitable for weldingsteels in two strength levels below that for which they havebeen approved.

3.1.7 Electrodes approved for strength levels Y47, Y55 andabove are also considered suitable for welding steels in only onestrength level below that for which they have been approved.

3.1.8 The welding current used is to be within the rangerecommended by the manufacturer and, where an electrodeis stated to be suitable for both a.c. and d.c., a.c. is to beused for the preparation of the test assemblies.

3.1.9 Where an electrode is submitted only for approvalfor fillet welding and to which the butt weld test provided in3.3 is not considered applicable, approval tests are to consistof the fillet weld tests as given in 3.5 and deposited metaltests with chemical analyses as given in 3.2.

3.2 Deposited metal test assemblies

3.2.1 The deposited metal test assemblies are to beprepared in the downhand position as shown in Fig. 11.3.1,one with 4 mm diameter electrodes and the other with 8 mmdiameter electrodes, or the largest size manufactured if this isless than 8 mm diameter. If an electrode is available in onediameter only, one test assembly is sufficient. Any of thegrades of steel in Table 11.1.1 may be used for the preparationof these assemblies, up to a strength level which is not morethan two levels above that for which approval is sought.

■ Section 2Mechanical testing procedures


2.1.1 Dimensions of test pieces for deposited metaltensile tests, butt weld tensile tests, bend tests and CharpyV-notch impact test are to machined to the dimensions andtolerances detailed in Chapter 2.


2.2.1 The procedures used for all tensile and impact testsare to comply with the requirements of Chapter 2.

2.2.2 Butt weld bend test specimens are to be tested atambient temperature and are to be bent through an angle of120° over a former having a diameter which relates to thethickness of the test specimen as detailed in subsequentSections. For each pair of bend test specimens, one specimen is to be tested with the face of the weld in tensionand the other with the root of the weld in tension.

2.2.3 Macro examinations are to be carried out onpolished and etched specimens at a maximum magnificationnot exceeding x10. The examination is to ensure completefusion, inter-run penetration and freedom of defects.

2.3 Re-testing procedures

2.3.1 Re-testing procedures are to comply with Ch 2,1.4.

■ Section 3Electrodes for manual and gravitywelding

3.1 General

3.1.1 Dependent on the results of the mechanical andother tests, approval will be allocated as one of the gradesfrom Table 11.1.1.

3.1.2 Approval of an electrode will be given in conjunc-tion with a welding technique indicated by a suffix ‘m’ formanual welding, ‘G’ for gravity or contact electrode and ‘p’for deep penetration electrode.

3.1.3 If the electrodes are in compliance with the require-ments of the hydrogen test given in 3.4, a suffix ‘H15’ or ‘H10’or ‘H5’ will be added to the grade mark. Table 11.3.1 shows themandatory levels of low hydrogen approval for the variousapproval grades.

3.1.4 For each strength level, electrodes which have satis-fied the requirements for a higher toughness grade areconsidered as complying with the requirements for a lower grade.


Approval of Welding Consumables Chapter 11Sections 2 & 3


Approval grades Low hydrogen grade required

1 (1N), 2 (2N), 3 (3N) NR2Y, 3Y, 4Y H15 (see Note 2)2Y40 to 5Y40 H153Y47 H10

3Y42 to 5Y42 H103Y46 to 5Y46 H103Y50 to 5Y50 H103Y55 to 5Y55 H53Y62 to 5Y62 H53Y69 to 5Y69 H5

11⁄2 Ni H1531⁄2 Ni H155 Ni NR (see Note 3)9 Ni NR (see Note 3)

NOTES1. NR – Not required. Approval may be obtained when requested.2. Optional in this case. If low hydrogen approval is not obtained,

there is a limitation on the carbon equivalent of the steel whichis permitted to be welded.

3. Assumes use of an austenitic, non-transformable, filler material.

Table 11.3.1 Minimum low hydrogen approvalrequirements for manual and gravityelectrodes

3.2.2 For Y47 grades, as an alternative to Fig. 11.3.1, thethickness of the plate used for the test assembly may betaken as 50 mm.

3.2.3 The weld metal is to be deposited in single- ormulti-run layers according to normal practice, and the direction of deposition of each layer is to alternate from eachend of the plate, each run of weld metal being not less than2 mm and not more than 4 mm thick. Between each run, theassembly is to be left in still air until it has cooled to less than250°C, the temperature being taken in the centre of the weld,on the surface of the seam. After being welded, the testassemblies are not to be subjected to any heat treatment,except in those higher strength grades where it is considerednecessary to use the welded joint in the stress-relieved(tempered) condition. In those cases, the code ‘sr’ will beadded to the approval grading.

3.2.4 The chemical analysis of the deposited weld metalin each deposited metal test assembly is to be supplied bythe manufacturer and is to include the content of all significant alloying elements. The results of the analysis arenot to exceed the limit values specified in the standards or bythe manufacturer, the narrower tolerances being applicable ineach case.

3.2.5 One tensile and three impact test specimens are tobe taken from each test assembly as shown in Fig. 11.3.1.Care is to be taken that the axis of the tensile test specimencoincides with the centre of the weld and the mid-thickness ofthe plates. The impact test specimens are to be cut perpendicular to the weld, with their axes 10 mm from theupper surface. The notch is to be positioned in the centre ofthe weld and cut in the face of the test specimen perpendicular to the surface of the plate.

3.2.6 The results of all tests are to comply with therequirements of Table 11.3.2 as appropriate.

3.3 Butt weld test assemblies

3.3.1 Butt weld assemblies, as shown in Fig. 11.3.2, areto be prepared for each welding position (downhand, horizontal-vertical, vertical-upward, vertical-downward, and overhead)for which the electrode is recommended by the manufacturer.In the case of electrodes for normal strength and higherstrength steels (up to 355 N/mm2 minimum specified yieldstrength), electrodes satisfying the requirements for down-hand and vertical-upward positions will be considered as alsocomplying with the requirements for the horizontal-verticalposition. In all other cases, approval for the horizontal-vertical position will require a butt weld to be made in thatposition and fully tested.

3.3.2 For Y47 grades, as an alternative to Fig. 11.3.2 thethickness of the plate used for the test assembly may betaken as 50 mm.

3.3.3 Where the electrode is to be approved only in thedownhand position, an additional test assembly is to beprepared in that position.



LLOYD’S REGISTER4

3450/03

20 mm

10 mm

16 mm

100 mm min. 30 mm 100 mm min.

Charpy V-notchspecimens taken atmid depth of weld Notch perpendicular

to surface of plate

Tensile

Chemical analysis

Line of cut for tensile test

80º

20 mm min80º

Fig. 11.3.1 Deposited metal test assembly

30º30º

15–2

0 m

m

55 mm

Discard

Charpy V-notch

Transverse tensile

Face bend

Root bend

Discard

2–3 mm

100 mm min. 100 mm min.

50 m

m30

mm

30 m

m

Fig. 11.3.2 Butt weld test assembly

3.3.4 The grades of steel used for the preparation of thetest assemblies are to be as follows:

Grade 1 (1N) electrodes AGrade 2 (2N) electrodes A, B or DGrade 3 (3N) electrodes A, B, D or EGrade 2Y electrodes AH32, AH36, DH32 or

DH36Grade 3Y electrodes AH32, AH36, DH32,

DH36, EH32 or EH36Grade 4Y electrodes AH32

AH36, DH32, DH36, EH32, EH36, FH32 or FH36

Grade 2Y40 electrodes AH40 or DH40Grade 3Y40 electrodes AH40, DH40 or EH40Grade 4Y40 electrodes AH40, DH40, EH40 or

FH40Grade 5Y40 electrodes AH40, DH40, EH40 or

FH40Grade 3Y47 electrodes EH47

Where Grade 32 higher tensile steel is used, the tensilestrength is to be not less than 490 N/mm2. The chemicalcomposition, including the content of grain refining elements,is to be reported in all cases where higher tensile steel is used.

3.3.5 For all other grades, the steel plates used are to beselected by reference to Table 11.1.1, and are to have at leasttheir chemical composition and tensile properties within thelimits specified for that grade in Chapter 3. The strength gradeused is to be the same as that for which approval is sought,and the toughness grade is to be no higher than that for whichapproval is also sought.




Table 11.3.2 Requirements for deposited metal tests (covered electrodes)


Grade Yield stressTensile strength

Elongation on 50 mm(see Note 3) N/mm2 minimum

N/mm2% minimum Test temperature

Average energy(see Note 1)

°C(see Note 2)J minimum

1N, 2N, 3N 305 400 – 560 22 +20, 0, –20 47

1Y, 2Y, 3Y, 4Y 375 490 – 660 22 +20, 0, –20, –40 47

2Y40, 3Y40, 400 510 – 690 22 0, –20, –40, –60 474Y40, 5Y40

3Y47 460 570 – 720 19 –20 53

3Y40 400 510 – 690 22 –20 473Y42 420 530 – 680 20 –20 473Y46 460 570 – 720 20 –20 473Y50 500 610 – 770 18 –20 503Y55 550 670 – 830 18 –20 553Y62 620 720 – 890 18 –20 623Y69 690 770 – 940 17 –20 69

4Y40 400 510 – 690 22 –40 474Y42 420 530 – 680 20 –40 474Y46 460 570 – 720 20 –40 474Y50 500 610 – 770 18 –40 504Y55 550 670 – 830 18 –40 554Y62 620 720 – 890 18 –40 624Y69 690 770 – 940 17 –40 69

5Y40 400 510 – 690 22 –60 475Y42 420 530 – 680 20 –60 475Y46 460 570 – 720 20 –60 475Y50 500 610 – 770 18 –60 505Y55 550 670 – 830 18 –60 555Y62 620 720 – 890 18 –60 625Y69 690 770 – 940 17 –60 69

11/2 Ni 375 460 22 –80 3431/2 Ni 375 420 25 –100 34

5 Ni 375 500 25 –120 349 Ni 375 600 25 –196 34

NOTES1. Single values are the minimum requirements.2. Energy values from individual impact test specimens are to comply with 1.4.3.3. Grade 1Y is not applicable to SMAW consumables referenced in Section 3.

3.3.12 The results of all tensile and impact tests are tocomply with the requirements of Table 11.3.3 as appropriate.The position of fracture in the transverse tensile test is to bereported.

3.3.13 The bend test specimens can be considered ascomplying with the requirements if, after bending, no crack orother open defect exceeding 3 mm in dimensions can be seenon the outer surface.

3.4 Hydrogen test

3.4.1 The hydrogen gradings are specified in 3.1.3. Thehydrogen grading required determines the method of testingpermitted as shown in Table 11.3.4. Where ISO 3690 is usedas the testing method, three test specimens are to beprepared and tested, and all three hydrogen test results mustbe below the maximum value for the hydrogen mark required.

3.5 Fillet weld test assemblies

3.5.1 Fillet weld assemblies as shown in Fig. 11.3.4 are tobe prepared for each welding position (horizontal-vertical,vertical-upward, vertical-downward or overhead) for which theelectrode is recommended by the manufacturer. The grade ofsteel used for the test assemblies is to be as detailed in 3.3.4.The length of the test assembly, L, is to be sufficient to allow atleast the deposition of the entire length of the largest diameter electrode being tested. Where an electrode issubmitted for approval of both butt and fillet welding, approvaltests are to include the deposited metal tests as given in 3.2,the butt weld tests as given in 3.3, and only one fillet weld testas given in subsequent paragraphs of this sub-Section weldedin the horizontal-vertical position.

3.5.2 For Y47 grades, as an alternative to Fig. 11.3.4, thethickness of the plate used for the test assembly may be takenas 50 mm.

3.3.6 The test assemblies are to be made by weldingtogether two plates of equal thickness (15 to 20 mm), not lessthan 100 mm in width and of sufficient length to allow thecutting out of test specimens of the prescribed number andsize. The plate edges are to be prepared to form a single V-joint, the included angle between the fusion faces being 60°and the root gap 2 to 3 mm. The root face is to be 0 to 2 mm.

3.3.7 The following welding procedure is to be adoptedin making the test assemblies:

Downhand (a). The first run with 4 mm diameter electrode. Remaining runs (except the last two layers)with 5 mm diameter electrodes or above according tothe normal welding practice with the electrodes. Theruns of the last two layers with the largest diameter of electrode manufactured or 8 mm whichever is thelesser.Downhand (b) (where a second downhand test isrequired). First run with 4 mm diameter electrode. Nextrun with an electrode of intermediate diameter of 5 mmor 6 mm, and the remaining runs with the largest diameter of electrode manufactured or 8 mm whicheveris the lesser.Horizontal-vertical. First run with 4 mm or 5 mm diameterelectrode. Subsequent runs with 5 mm diameter electrodes.Vertical-upward and overhead. First run with3,25 mm diameter electrode. Remaining runs with4 mm diameter electrodes or possibly with 5 mm if thisis recommended by the manufacturer for the positionsconcerned.Vertical-downward. If the electrode being tested isintended for vertical welding in the downward direction,this technique is to be adopted for the preparation ofthe test assembly using electrode diameters as recom-mended by the manufacturer.

3.3.8 For all assemblies, the back sealing runs are to bemade with 4 mm diameter electrodes in the welding positionappropriate to each test sample, after cutting out the root runto clean metal. For electrodes suitable for downhand weldingonly, the test assemblies may be turned over to carry out theback sealing run.

3.3.9 Normal welding practice is to be used and,between each run, the assembly is to be left in still air until ithas cooled to less than 250°C, the temperature being taken inthe centre of the weld, on the surface of the seam. After beingwelded, the test assemblies are not to be subjected to anyheat treatment, except in those higher strength grades whereit is considered necessary to use the welded joint in thestress-relieved (tempered) condition. In those cases, the code‘sr’ will be added to the approval grading.

3.3.10 It is recommended that the welded assemblies besubjected to a radiographic examination to ascertain if thereare any defects in the weld prior to the preparation of testspecimens.

3.3.11 The test specimens as shown in Figs. 11.3.2 and11.3.3 are to be prepared from each test assembly.



LLOYD’S REGISTER6

Notch perpendicularto surface of plate

Test specimen taken frommiddle of plate thickness

15–2

0 m

m

55 mm

Fig. 11.3.3Butt weld test assembly position of

impact test specimens




Table 11.3.3 Requirements for butt weld tests (covered electrodes)


Bend test Average energyGrade Tensile strength ratio: (see Note 1)

(see Note 3) N/mm2 Test temperature J minimum°C

All positions(see Note 2)

1N, 2N, 3N 400 3 +20, 0, –20 47 (34)

1Y, 2Y, 3Y, 4Y 490 3 +20, 0, –20, –40 47 (34)

2Y40, 3Y40, 4Y40, 5Y40 510 3 0, –20, –40, –60 47 (39)

3Y47 570 – 720 4 –20 53

3Y40 510 3 –20 47 (39)3Y42 530 – 680 4 –20 473Y46 570 – 720 4 –20 473Y50 610 – 770 4 –20 503Y55 670 – 830 5 –20 553Y62 720 – 890 5 –20 623Y69 770 – 940 5 –20 69

4Y40 510 3 –40 47 (39)4Y42 530 – 680 4 –40 474Y46 570 – 720 4 –40 474Y50 610 – 770 4 –40 504Y55 670 – 830 5 –40 554Y62 720 – 890 5 –40 624Y69 770 – 940 5 –40 69

5Y40 510 3 –60 395Y42 530 – 680 4 –60 475Y46 570 – 720 4 –60 475Y50 610 – 770 4 –60 505Y55 670 – 830 5 –60 555Y62 720 – 890 5 –60 625Y69 770 – 940 5 –60 69

11/2 Ni 490 3 –80 2731/2 Ni 450 3 –100 27

5 Ni 540 4 –120 279 Ni 640 4 –196 27

NOTES1. Energy values from individual impact test specimens are to comply with 1.4.3.2. Values in ( ) apply only to welds made in the vertical position with upward progression.3. Grade 1Y is not applicable to SMAW consumables referenced in Section 3.

Dt

150 mm

20 mm

App

rox.

150

mm

20 m

m

25 mm 25 mm 25 mm

ApproximatelyL2 Approximately

L2

L

Fig. 11.3.4 Fillet weld test assembly

Hydrogen Grade Permitted Method

H15 ISO 3690 (or Glycerine)(See Note)

H10 ISO 3690H5 ISO 3690

NOTEISO method preferred.

Table 11.3.4 Permitted methods for obtaining lowhydrogen grading

3.6.2 Electrodes designed solely for the deep penetrationwelding technique will be approved as complying with Grade 1 requirements only and will be given the suffix ‘p’.

3.6.3 Where a manufacturer recommends that an electrode having deep penetrating properties can also beused for downhand butt welding of thicker plates withprepared edges, the electrode will be treated as a normalpenetration electrode, and the full series of tests in the down-hand position is to be carried out, together with the deeppenetration tests given in 3.7 and 3.8.

3.6.4 Where a manufacturer desires to demonstrate thatan electrode, in addition to its use as a normal penetrationelectrode, also has deep penetrating properties when usedfor downhand butt welding and horizontal fillet welding, the additional tests given in 3.7 and 3.8 are to be carried out.

3.6.5 Electrodes approved for both normal and deeppenetration welding will have the suffix ‘p’ added after theappropriate grade mark for normal penetration welding.

3.6.6 Where the manufacturer prescribes a different welding current and procedure for the electrode when usedas a deep penetration electrode and a normal penetration electrode, the recommended current and procedure are to beused when making the test assemblies in each case.

3.7 Deep penetration butt weld test assemblies

3.7.1 Two plates of thickness equal to twice the diameterof the core of the electrode plus 2 mm are to be butt weldedtogether with one downhand run of welding from each side.The plates are to be not less than 100 mm wide and of sufficient length to allow the cutting out of the test specimensof the correct number and size as shown in Fig. 11.3.6. GradeA steel is to be used for these test assemblies. The joint edgesare to be prepared square and smooth and, after tacking, thegap is not to exceed 0,25 mm. The test assembly is to bewelded using an 8 mm diameter electrode, or the largestdiameter manufactured if this is less than 8 mm and theassembly is to be allowed to cool below 50°C between runs.

3.7.2 The test specimens as shown in Figs. 11.3.3 and11.3.6 are to be prepared from each test assembly.

3.7.3 The results of tensile and impact tests are tocomply with the requirements of Table 11.3.3 for Grade 1electrodes. The position of fracture in the tensile test is to bereported. The bend test specimens are to be in accordancewith 3.3.13.

3.7.4 The discards at the end of the welded assembliesare to be not more than 35 mm wide. The joints of thesediscards are to be polished and etched and must showcomplete fusion and inter-penetration of the weld beads. Ateach cut in the test assembly, the joints are also to be examined to ensure that complete fusion has taken place.

3.5.3 The electrode sizes to be used are the maximumand minimum diameters recommended by the manufacturerfor fillet welding. The first side is to be welded using the maximum diameter. The second side is to be welded onlyafter the assembly has been allowed to cool below 50°Cusing the minimum diameter. The size of these single run filletwelds will, in general, be determined by the electrode size andthe welding current employed during testing and shouldrepresent the range of fillet weld bead sizes recommended bythe manufacturer.

3.5.4 Each test assembly is to be sectioned to form threemacro-sections, each about 25 mm thick. These are to beexamined for root penetration, satisfactory profile, freedomfrom cracking and reasonable freedom from porosity and slaginclusions. Any undercut is not to exceed 0,5 mm in depth.Convexity or concavity of the profile is not to exceed one-tenth of the fillet bead throat dimension. All such observationsare to be reported.

3.5.5 Hardness measurements are to be made on thecentral macro-section only, as shown in Fig. 11.3.5. Theresults are to be reported.

3.5.6 One of the remaining sections of the assembly is tohave the weld on the first side gouged or machined to facilitate breaking the fillet weld on the second side by closingthe two plates together, subjecting the root of the weld totension. On the other remaining section, the weld on thesecond side is to be gouged or machined and the sectionfractured using the same procedure. The fractured surfacesare to be examined. They are to show satisfactory penetra-tion, freedom from cracks and reasonable freedom fromporosity and this should be reported.

3.6 Electrodes designed for deep penetrationwelding

3.6.1 Where an electrode is designed solely for the deeppenetration welding of downhand butt joints and horizontal-vertical fillets in normal tensile strength steel, only the testsdetailed in 3.7 and 3.8 are required for approval purposes.



LLOYD’S REGISTER8

Position ofhardness tests

3450/04

Fig. 11.3.5Hardness tests for fillet weld test assembly

3.8.3 The welded assembly is to be cut by sawing ormachining within 35 mm of the ends of the fillet welds, andthe joints are to be polished and etched. The welding of thefillet made with a 4 mm diameter electrode is to show a penetration of 4 mm (see Fig. 11.3.7) and the correspondingpenetration of the fillet made with the maximum diameter ofelectrode manufactured is to be reported.

3.9 Electrodes designed for gravity or contactwelding

3.9.1 Approval for welding using the gravity, ‘G’, technique is available for welding only normal strength andhigher tensile steels up to and including Grade 36.

3.9.2 Where an electrode is submitted solely for approvalfor use in contact welding using automatic gravity or similarwelding devices, deposited metal tests, butt weld tests and,where appropriate, fillet weld tests similar to those for normalmanual electrodes are to be carried out using the process forwhich the electrode is recommended by the manufacturer.

3.9.3 Where an electrode is submitted for approval foruse in contact welding using automatic gravity or similar welding devices in addition to normal manual welding, buttweld and, where appropriate, fillet weld tests, using the gravity or other contact device as recommended by themanufacturer, are to be carried out in addition to the normalapproval tests.

3.10 Annual tests

3.10.1 For normal penetration electrodes, the annual testsare to consist of two deposited metal test assemblies. Theseare to be prepared and tested in accordance with 3.2. If anelectrode is available in one diameter only, one test assemblyis sufficient.



LLOYD’S REGISTER

3.8 Deep penetration fillet weld test assemblies

3.8.1 A fillet weld assembly is to be prepared as shown inFig. 11.3.7 with plates about 12,5 mm in thickness. The welding is to be carried out with one run for each fillet withplate A in the horizontal plane during the welding operations.The length of the fillet is to be 160 mm and the gap betweenthe plates is to be not more than 0,25 mm. Grade A steel is tobe used for these test assemblies.

3.8.2 The fillet weld on one side of the assembly is to becarried out with a 4 mm diameter electrode, and that on theother side with the maximum diameter of electrode manufac-tured. The welding current used is to be within the rangerecommended by the manufacturer, and the welding is to becarried out using normal welding practice except that theassembly is to be allowed to cool below 50°C between runs.

Thickness of plate twicecore of electrode plus 2 mm

100 mm min.100 mm min.

0,25 mm max.

Discard

Transverse tensile

Transverse tensile

Root bend

Face bend

Charpy V-notch

Discard

35 m

m30

mm

30 m

m50

mm

50 m

m35

mm

Fig. 11.3.6Deep penetration butt weld test assembly

9

4 mm min. Penetration tobe reported

12,5 mm

Plate A

Maximum size ofelectrode manufactured

4 mm electrode

0,25 mm

12,5 mm

Fig. 11.3.7Deep penetration fillet weld test assembly

3.10.2 Where an electrode is approved solely for deeppenetration welding, the annual test is to consist of one buttwelded test assembly. This is to be prepared and tested inaccordance with 3.7.

3.10.3 Where an electrode is approved for both normaland deep penetration welding, annual tests as detailed in3.10.1 and 3.10.2 are to be carried out.

3.10.4 Where an electrode is approved solely for gravity orcontact welding, the annual test is to consist of one depositedmetal test assembly using the gravity or other contact deviceas recommended by the manufacturer.

3.10.5 Where an electrode is approved for both manualand gravity welding, annual tests as detailed in 3.10.1 and3.10.4 are to be carried out.

■ Section 4Wire-flux combinations forsubmerged-arc automatic welding

4.1 General

4.1.1 Wire-flux combinations for single and multiple electrode submerged-arc automatic welding, without the useof temporary backing, are divided into the following two categories:• For use with the multi-run technique.• For use with the two-run technique.Where particular wire-flux combinations are intended for welding with both techniques, tests are to be carried out foreach technique.

4.1.2 Dependent on the results of mechanical and othertests, approval will be allocated as one of the grades fromTable 11.1.1.

4.1.3 The suffixes T or M will be added after the grademark to indicate approval for the two-run technique or, multi-run technique respectively.

4.1.4 Wire-flux combinations satisfying the requirementsfor multi-run or two-run techniques will also be approved forfillet welding in the downhand and horizontal-vertical position,subject to agreement by the manufacturer.

4.1.5 If the consumable combination is in compliancewith the requirements of the hydrogen test given in 3.4, asuffix H15, H10 or H5 will be added to the grade. Table 11.4.1shows the mandatory levels of low hydrogen approval for thevarious approval grades.

4.1.6 For each strength level, wire-flux combinations whichhave satisfied the requirements for a higher toughness gradeare considered as complying with the requirements for a lowergrade.

4.1.7 Wire-flux combinations approved with multi-runtechnique for normal and higher strength levels up to andincluding ‘Y’ are also considered suitable for welding steels inthe three strength levels below that for which they have beenapproved.

4.1.8 Wire-flux combinations approved with multi-runtechnique for strength levels Y40 to Y50, but excluding Y47are also considered suitable for welding steels in two strengthlevels below that for which they have been approved.

4.1.9 Wire-flux combinations approved with multi-runtechnique for strength levels Y47, Y55 and above are alsoconsidered suitable for welding steels in only one strengthlevel below that for which they have been approved.

4.1.10 Wire-flux combinations with two-run techniqueapproval are not considered suitable for welding steels of anyother strength level with that technique, see 4.5.1.

4.1.11 The welding current may be either a.c. or d.c. (electrode positive or negative) according to the recommen-dation of the manufacturer. If both a.c. and d.c. arerecommended, a.c. is to be used for the tests.

4.1.12 Wire-flux combinations for multiple electrodesubmerged-arc welding will be subject to separate approvaltests. These are to be carried out generally in accordance withthe requirements of this Section.

4.1.13 Wire-flux combinations are not naturally low hydrogen in character, but for the lower strength grades ofsteel low hydrogen testing is not normally a requirement forapproval. With higher strength steels it is more important and Table 11.4.1 shows the mandatory minimum low hydrogenstatus required for approval of wire-flux combinations.




Table 11.4.1 Minimum low hydrogen approvalrequirements for wire-fluxcombinations

Approval grade‘H’ grade ‘H’ grade for

for Multi-run Two-run

1 (1N), 2 (2N), 3 (3N) NR NR1Y, 2Y, 3Y, 4Y NR NR2Y40 to 5Y40 H15 NR3Y47 H10 H15

3Y42 to 5Y42 H10 H153Y46 to 5Y46 H10 H153Y50 to 5Y50 H10 H103Y55 to 5Y55 H5 H103Y62 to 5Y62 H5 H53Y69 to 5Y69 H5 H5

11/2 Ni H15 NR31/2 Ni H15 NR5 Ni (see Note 2) NR NR9 Ni (see Note 2) NR NR

NOTES1. NR – Not required. Approval can be obtained when requested.2. Assumes use of an austenitic, non-transformable, filler

material.

4.2 Approval tests for multi-run technique

4.2.1 Where approval for use with the multi-run techniqueis requested, deposited metal and butt weld tests are to becarried out.

4.3 Deposited metal test assemblies (multi-runtechnique)

4.3.1 One deposited metal test assembly is to beprepared as shown in Fig. 11.4.1, using any of the grades ofsteel in Table 11.1.1 up to a strength level which is not morethan two levels above that for which approval is sought.

4.3.2 For Y47 grades, as an alternative to Fig. 11.4.1, thethickness of the plate used for the test assembly may betaken as 50 mm.




4.3.3 The bevelling of the plate edges is to be carried outby machining or mechanised gas cutting. In the latter caseany remaining scale is to be removed from the bevellededges.

4.3.4 Welding is to be in the downhand position, and thedirection of deposition of each run is to alternate from eachend of the plate. After completion of each run, the flux andwelding slag are to be removed. Between each run, the assembly is to be left in still air until it has cooled to less than250°C, the temperature being taken in the centre of the weld,on the surface of the seam. The thickness of the layer is to benot less than the diameter of the wire nor less than 4 mm,unless it is clearly stated as part of the consumable manufacturer’s published recommendations.

4.3.5 The welding conditions (amperage, voltage and rateof travel) are to be in accordance with the recommendations ofthe manufacturer and are to conform with normal good weldingpractice for multi-run welding.

4.3.6 The chemical analysis of the deposited weld metal ineach test assembly is to be supplied by the manufacturer andis to include the content of all significant alloying elements. Theresults of the analysis are not to exceed the limit values specified in the standards or by the manufacturer, the narrowertolerances being applicable in each case.

4.3.7 Two longitudinal tensile and three impact test specimens are to be taken from each test assembly as shownin Fig. 11.4.1. Care is to be taken that the axes of the tensiletest specimens coincide with the centre of the weld and themid-thickness of the plates. The impact test specimens areto be cut perpendicular to the weld with their axes 10 mmfrom the upper surface. The notch is to be positioned in thecentre of the weld and cut in the face of the test specimenperpendicular to the surface of the plate.

4.3.8 In those cases where two-run technique approval isalso sought, only one longitudinal tensile specimen need beprepared and tested from this assembly.

4.3.9 The results of all tests are to comply with therequirements of Table 11.4.2, as appropriate.

4.4 Butt weld test assemblies (multi-run technique)

4.4.1 One butt weld test assembly is to be prepared asshown in Fig. 11.4.2.

200 mm

12 mm16 mm

Tack weld

50 mm

80° 80°

Longitudinaltensile test

Chemical analysis

30 mmCharpy tests

10 m

m10

mm

10 m

m

10 mm10 mm

Line of cut

30 mm

Longitudinaltensile test

V

V

V

20 mm


Grade 5Y40 wire-flux combinations AH40, DH40 EH40, FH4

Grade 3Y47 wire-flux combinations EH47 Where Grade 32 higher tensile steel is used, the tensilestrength is to be not less than 490 N/mm2. The chemicalcomposition, including the content of grain refining elements,is to be reported in all cases where higher tensile steel is used.

4.4.3 For all other grades, the steel plates used are to beselected by reference to Table 11.1.1, and are to have at leasttheir chemical composition and tensile properties within thelimits specified for that grade in Chapter 3. The strength gradeused is to be the same as that for which approval is sought,and the toughness grade is to be no higher than that for whichapproval is also sought.

4.4.2 The grade of steel used for the preparation of thetest assembly are to be as follows:

Grade 1 wire-flux combination AGrade 2 wire-flux combinations A, B or DGrade 3 wire-flux combinations A, B, D or EGrade 1Y wire-flux combination AH32 or AH36Grade 2Y wire-flux combinations AH32, AH36,

DH32 or DH36Grade 3Y wire-flux combinations AH32, AH36,

DH32, DH36, EH32 or EH36

Grade 4Y wire-flux combinations AH32, AH36, DH32, DH36, EH32, EH36,FH32 or FH36

Grade 2Y40 wire-flux combination AH40 or DH40Grade 3Y40 wire-flux combinations AH40, DH40 or

EH40Grade 4Y40 wire-flux combinations AH40, DH40,

EH40 or FH40

Charpy V-notch impact testsYield stress Tensile Elongation on

Grade N/mm2 strength 50 mm Test Average energyminimum N/mm2 % minimum temperature (see Note)

°C J minimum

1N, 2N, 3N 305 400 – 560 22 +20, 0, –20 34

1Y, 2Y, 3Y, 4Y 375 490 – 660 22 +20, 0, –20, –40 34

2Y40, 3Y40, 400 510 – 690 22 0, –20, –40, –60 394Y40, 5Y40

3Y47 460 570 – 720 19 –20 53

3Y40 400 510 – 690 22 –20 393Y42 420 530 – 680 20 –20 473Y46 460 570 – 720 20 –20 473Y50 500 610 – 770 18 –20 503Y55 550 670 – 830 18 –20 553Y62 620 720 – 890 18 –20 623Y69 690 770 – 940 17 –20 69

4Y40 400 510 – 690 22 –40 394Y42 420 530 – 680 20 –40 474Y46 460 570 – 720 20 –40 474Y50 500 610 – 770 18 –40 504Y55 550 670 – 830 18 –40 554Y62 620 720 – 890 18 –40 624Y69 690 770 – 940 17 –40 69

5Y40 400 510 –690 22 –60 395Y42 420 530 – 680 20 –60 475Y46 460 570 – 720 20 –60 475Y50 500 610 – 770 18 –60 505Y55 550 670 – 830 18 –60 555Y62 620 720 – 890 18 –60 625Y69 690 770 – 940 17 –60 69

11⁄2 Ni 375 460 22 –80 3431⁄2 Ni 375 420 25 –100 345 Ni 375 500 25 –120 349 Ni 375 600 25 –196 34

NOTEEnergy values from individual impact test specimens are to comply with 1.4.3.

Table 11.4.2 Requirements for deposited metal tests (wire-flux combinations)




4.4.4 The plate edges are to be prepared to form a singleV-joint, the included angle between the fusion faces being 60°and the root face being 4 mm. The bevelling of the plate edgesis to be carried out by machining or mechanised gas cutting.In the latter case, any remaining scale is to be removed frombevelled edges.

4.4.5 Welding is to be carried out in the downhand position by the multi-run technique, and the welding conditionsare to be the same as those adopted for the deposited metaltest assembly. The back sealing run is to be applied in thedownhand position after cutting out the root run to clean metal.

4.4.6 It is recommended that the welded assembly besubjected to a radiographic examination to ascertain if there areany defects in the weld prior to the preparation of test specimens.

4.4.7 The test specimens as shown in Fig. 11.3.3 and Fig. 11.4.2 are to be prepared from each test assembly.



LLOYD’S REGISTER

4.4.8 The results of all tensile and impact tests are tocomply with the requirements of Table 11.4.3, as appropriate.The position of fracture of the transverse tensile test is to bereported.

4.4.9 The bend test specimens can be considered ascomplying with the requirements if, after bending, no cracksor other open defects exceeding 3 mm in dimension can beseen on the outer surface.

4.5 Approval tests for two-run technique

4.5.1 Where approval for use with the two-run techniqueis requested, two butt weld test assemblies are to be preparedand tested using plates of the strength level for which approvalis required. Each strength level requires separate approval.

4.5.2 Two welded assemblies are to be made from a pairof plates of matching thicknesses. The thickness of the thickerpair of plates will be the maximum for which the approval isvalid. The second assembly is to be welded from plates havingapproximately half of the thickness of the first assembly.

4.6 Butt weld test assemblies (two-run technique)

4.6.1 The grade of steel used for the preparation of thetest assemblies is not to be of any higher grade (impacttoughness) than that for which approval is required. Thechemical composition, including the content of grain refiningelements, and the strength properties of the plates used, areto be reported.

4.6.2 The maximum diameter of wire and the edgepreparation to be used are to be in accordance with Table 11.4.4. Small deviations in the edge preparation may beallowed if requested by the manufacturer. The bevelling of theplate edges is to be performed by machining or mechanisedgas cutting. In the latter case, any remaining scale is to beremoved from the bevelled edges. The root gap should notexceed 0,7 mm.

4.6.3 Each butt weld is to be welded in two runs, one fromeach side, using amperages, voltages and travel speeds inaccordance with the recommendations of the manufacturerand normal good welding practice. After completion of the firstrun, the flux and welding slag are to be removed and theassembly is to be left in still air until it has cooled to less than100°C, the temperature being taken in the centre of the weld,on the surface of the seam.

4.6.4 It is recommended that the butt weld assemblies besubjected to radiographic examination to ascertain if there areany defects in the weld prior to the preparation of test specimens.

4.6.5 The test specimens, as shown in Fig. 11.4.3 and Fig. 11.4.4, are to be prepared from each test assembly, exceptas detailed in 4.6.8. The edges of two of the discards are to bepolished and etched, and must show complete fusion and inter-run penetration of the welds. At each cut in the testassembly, the edges are also to be examined to ensure thatcomplete fusion has taken place.

13

60°

4 mm

20–2

5 m

m

150 mm min. 150 mm min.

50 m

m30

mm

30 m

m10 m

m

10 m

m

10 m

m 30 m

m30

mm

50 m

m

Transverse tensile

Charpy V-notch

Face bend

Root bend

Transverse tensile

Root bend

Face bend

V

V

V

Fig. 11.4.2Butt weld test assembly (multi-run technique)




PlateMaximum

thicknessRecommended diameter

mmdiameter of wire

mm

12,5 5

20–25 6

35–40 7

Table 11.4.4 Butt weld assembly preparation

60°

8 m

m m

in.

70°

70°7 m

m m

in.

x

x

4.6.6 The results of transverse tensile and impact testsare to comply with the requirements of Table 11.4.3 as appro-priate. The position of fracture of the transverse tensile tests isto be reported.

4.6.7 The bend test specimens can be considered ascomplying with the requirements if, after bending, no crack orother open defects exceeding 3 mm in dimensions can beseen on the outer surface. One of the specimens from eachassembly is to be tested with the side first welded in tension,and the second specimen with the other side in tension.

4.6.8 The longitudinal tensile specimen shown in Fig. 11.4.3 is to be prepared from the thicker assembly, evenin those cases where multi-run technique approval is alsosought. This test specimen is to be machined to the dimensions shown in Ch 11,2.1.1, and the longitudinal axis isto coincide with the centre of the weld about 7 mm below theplate surface on the side from which the second run is made.The test specimen may be given a hydrogen release treatmentin accordance with 2.1.1. The results of this test are to complywith the requirements of Table 11.4.2.

Charpy V-notch impact testsTensile Bend test

Grade strength ratio: Test Average energy N/mm2 temperature (see Notes 1 and 2)

°C J minimum

1N, 2N, 3N 400 3 +20, 0, –20 34

1Y, 2Y, 3Y, 4Y 490 3 +20, 0, –20, –40 34

2Y40, 3Y40, 4Y40, 5Y40 510 3 0, –20, –40, –60 39

3Y47 570 – 720 4 –20 53

3Y40 510 3 –20 393Y42 530 – 680 4 –20 47 (41)3Y46 570 – 720 4 –20 473Y50 610 – 770 4 –20 503Y55 670 – 830 5 –20 553Y62 720 – 890 5 –20 623Y69 770 – 940 5 –20 69

4Y40 510 3 –40 394Y42 530 – 680 4 –40 47 (41)4Y46 570 – 720 4 –40 474Y50 610 – 770 4 –40 504Y55 670 – 830 5 –40 554Y62 720 – 890 5 –40 624Y69 770 – 940 5 –40 69

5Y40 510 3 –60 395Y42 530 – 680 4 –60 47 (41)5Y46 570 – 720 4 –60 475Y50 610 – 770 4 –60 505Y55 670 – 830 5 –60 555Y62 720 – 890 5 –60 625Y69 770 – 940 5 –60 69

11⁄2 Ni 490 3 –80 2731⁄2 Ni 450 3 –100 275 Ni 540 4 –120 279 Ni 640 4 –196 27

NOTES1. Energy values from individual impact test specimens are to comply with 1.4.3.2. Values in ( ) apply only to two-run technique impact test specimens.

Dt

Table 11.4.3 Requirements for butt weld tests (wire-flux combinations)

4.6.9 The chemical analysis of the weld metal of thesecond run in each assembly is to be determined andreported. This is to include the content of all significantelements. The results of the analysis are not to exceed the limit values specified in the standards or by the manufacturer,the narrower tolerances being applicable in each case.

4.7 Annual tests

4.7.1 Annual tests are to consist of at least the following:(a) For wire-flux combinations approved for the multi-run

technique, one deposited metal test assembly.(b) For wire-flux combinations approved for the two-run

technique, one butt weld test assembly using plate material 20 to 25 mm in thickness. For Y47 the thicknessof plate material may be taken as 50 mm.

4.7.2 The deposited metal assemblies are to be preparedand tested in accordance with 4.3, except that only one longitudinal tensile, three impact test specimens and a chemical analysis are required.

4.7.3 The butt weld test assemblies are to be preparedand tested in accordance with 4.6, except that only one transverse tensile, two bend, three impact test specimens anda chemical analysis are required. One longitudinal tensile testspecimen is also to be prepared where the wire-flux combination is approved solely for the two-run technique.

4.7.4 Where a wire-flux combination is approved for weldinga range of steels with different specified minimum strengthlevels, steel of the highest strength approved is to be used forthe preparation of the butt weld assembly required by 4.7.1(b).




Second runChemical analysis

Chemical analysis

x

10 m

m

55 mm

Second run

Second run

2 mm

10 m

m

2 mm

10 m

m

12–1

5 m

m20

–25

mm

35–4

0mm

Fig. 11.4.4Butt weld test assembly (two-run technique):

position of impact test specimens

MacroDiscard

Macro Discard

150 mm min.150 mm min.

Longitudinal tensile

Transverse tensile

Transverse tensile

Bend

Bend

Charpy V–notch

5119/01

Fig. 11.4.3Butt weld test assembly (two-run technique)

5.1.7 For wires intended for automatic welding, the suffixesT or M will be added after the grade mark to indicate approvalfor two-run or multi-run welding techniques, respectively.

5.1.8 For wires intended for both semi-automatic andautomatic welding, the suffices will be added in combination.

5.1.9 Solid wire-gas combinations are considered naturally low hydrogen in character and qualify for ‘H15’approval without testing. This is not so for cored wires andcontinuous coated wires which must be tested if there is aneed for low hydrogen approval. For the lower strengthgrades of steel, low hydrogen testing is not normally a require-ment for approval. With higher strength steels, it is moreimportant and Table 11.5.1 shows the mandatory minimum lowhydrogen status required for approval of wire-gas combina-tions.

5.1.10 The testing methods to be used for low hydrogenapproval are to be in accordance with 3.4, modified to use themanufacturer’s recommended welding conditions and adjustingthe deposition rate to give a weld deposit weight per samplesimilar to that deposited when using manual electrodes.

5.1.11 Where applicable, the approved combination willname either the specific gas composition or its trade name,but in either case the composition of the shielding gas is tobe reported. Unless otherwise agreed, additional approvaltests are required when a shielding gas is used other thanthat used for the original approval tests. However a wire andgas combination approved with an argon/carbon dioxideshielding gas where the carbon dioxide is between 15-25 percent is also approved for other combinations of argon/carbondioxide, provided the carbon dioxide content is within therange 15-25 per cent. The range of approval is limited toferritic consumables in solid wire, flux cored and coated wireforms and subject to the agreement of the consumablemanufacturer and LR.

■ Section 5Wires and wire-gas combinationsfor manual, semi-automatic andautomatic welding

5.1 General

5.1.1 Wire-gas combinations and flux-cored or flux-coatedwires (for use with or without a shielding gas) are divided intothe following categories for the purposes of approval testing:(a) For use in manual multi-run welding with the inert gas

tungsten arc welding process (GTAW).(b) For use in semi-automatic multi-run metal arc welding.(c) For use in single electrode multi-run automatic metal arc

and GTAW welding.(d) For use in single electrode two-run automatic metal arc

and GTAW welding.

5.1.2 The term ‘manual’, is used to describe the techniquewhere the gas-shielded tungsten arc torch is held in one handand the filler is added separately by the other hand.

5.1.3 The term ‘semi-automatic’ is used to describeprocesses in which the weld is made manually by a welderholding a gun through which the wire is continuously fed.

5.1.4 In the GTAW process, ‘automatic’ refers to the fullymechanised control and application of both torch and separatefiller wire.

5.1.5 Dependent on the results of mechanical and othertests, approval will be allocated as one of the grades from Table 11.1.1.

5.1.6 A suffix S will be added after the grade mark to indicate approval for semi-automatic multi-run welding.




Table 11.5.1 Minimum low hydrogen approval requirements for wires and wire-gas combinations

‘H’ grade for‘H’ grade for ‘H’ grade forApproval grade m and SM technique T techniquetechniques

1 (1N), 2 (2N), 3 (3N) NR NR NR 1Y, 2Y, 3Y, 4Y H15 (see Note 2) NR NR 2Y40 to 5Y40 H15 H15 NR 3Y47 H10 H10 H10

3Y42 to 5Y42 H10 H10 H15 3Y46 to 5Y46 H10 H10 H15 3Y50 to 5Y50 H10 H10 H10 3Y55 to 5Y55 H5 H5 H10 3Y62 to 5Y62 H5 H5 H5 3Y69 to 5Y69 H5 H5 H5

11/2 Ni H15 H15 NR 31/2 Ni H15 H15 NR 5 Ni NR (see Note 3) NR NR 9 Ni NR (see Note 3) NR NR

NOTES 1. NR – Not required. Approval may be obtained when requested.2. Optional in this case. If low hydrogen approval is not obtained, there is a limitation on the carbon equivalent of the steel which is

permitted to be welded. 3. Assumes use of an austenitic, non-transformable, filler material.

5.2.6 Butt weld assemblies as shown in Fig. 11.3.2 are to be prepared for each welding position for which the wire isto be approved. In the case of approvals for normal andhigher strength steels (up to 355 N/mm2 minimum specifiedyield strength), tests satisfying the requirements in both thedownhand and vertical-upward positions will be consideredas having also satisfied the requirements for the horizontal-vertical position. In all other cases, approval in the horizontal-vertical position will require a butt weld to be made in thatposition and be fully tested.

5.2.7 The downhand assembly is to be welded using, forthe first run, wire of the smallest diameter to be approved and,for the remaining runs, wire of the largest diameter to beapproved.

5.2.8 Where approval is requested only in the downhandposition, an additional butt weld assembly is to be prepared inthat position using, if possible, wires of different diameter fromthose required by 5.2.7. If only one wire diameter is to beapproved, this second downhand butt weld should be madeusing either larger or smaller beads than the first assembly.

5.2.9 The butt weld assemblies, in positions other thandownhand, are to be welded using, for the first run, wire ofthe smallest diameter to be approved, and for the remainingruns, the largest diameter of wire recommended by the manu-facturer for the position concerned.

5.2.10 Fillet weld test assemblies as detailed in 3.5 are tobe prepared, examined and tested.

5.2.11 Low hydrogen approval tests are to be carried outif required by 5.1.9.

5.2.12 Test specimens from each assembly are to beprepared and tested in accordance with the requirements of3.2 and 3.3.

5.3 Approval tests for multi-run automaticwelding

5.3.1 Approval tests for multi-run automatic welding areto be carried out generally in accordance with the require-ments of Section 4, except as required by 5.3, using themulti-run automatic welding technique for the preparation ofall test assemblies.

5.3.2 One deposited metal test assembly is to beprepared as shown in Fig. 11.4.1. Welding is to be as detailedin 4.3.4, except that the thickness of each layer is to be notless than 3 mm, unless it is clearly stated as part of theconsumable manufacturer’s published recommendations.

5.3.3 For Y47 grades, as an alternative to Figs. 11.4.1and 11.4.2, the thickness of the plate used for the test assembly may be taken as 50 mm.

5.3.4 One butt weld test assembly is to be prepared asshown in Fig. 11.4.2 for each welding position to be approvedfor the automatic multi-run technique.

5.1.12 Wires and wire-gas combinations for multiple electrode automatic welding will be subject to separate approvaltests. Any proposals are to be submitted for consideration.

5.1.13 Wires and wire-gas combinations approved withmulti-run technique for normal and higher strength levels up toand including ‘Y’ are also considered suitable for welding steelsin the three strength levels below that for which they have beenapproved.

5.1.14 Wires and wire-gas combinations approved withmulti-run technique for strength levels Y40 to Y50, but excluding Y47 are also considered suitable for welding steelsin two strength levels below that for which they have beenapproved.

5.1.15 Wires and wire-gas combinations approved withmulti-run technique for strength levels Y47, Y55 and above arealso considered suitable for welding steels in only one strengthlevel below that for which they have been approved.

5.1.16 Wires and wire-gas combinations with two-run technique approval are not considered suitable for weldingsteels of any other strength level with that technique, see 5.4.1.

5.2 Approval tests for manual and semi-automaticmulti-run welding

5.2.1 Approval tests for manual (GTAW) and semi-automatic multi-run welding are to be carried out generally inaccordance with the requirements of Section 3, except asrequired by 5.2, using the respective technique for the preparation of all test assemblies.

5.2.2 Two deposited metal test assemblies are to beprepared in the downhand position as shown in Fig. 11.3.1, oneusing the smallest diameter, and the other using the largestdiameter of wire for which approval is required. Where only onediameter is manufactured, only one deposited metal assemblyis to be prepared.

5.2.3 For Y47 grades, as an alternative to Figs. 11.3.1 to11.3.4, the thickness of the plate used for the test assemblymay be taken as 50 mm.

5.2.4 The weld metal is to be deposited according to thepractice recommended by the manufacturer, and the thickness of each layer of weld metal is to be between 2 mmand 6 mm, unless it is clearly stated as part of the consumable manufacturer’s published recommendations.

5.2.5 The chemical analysis of the deposited weld metalin each test assembly is to be supplied by the manufacturerand is to include the content of all significant alloyingelements. The results of the analysis are not to exceed thelimit values specified in the standards or by the manufacturer,the narrower tolerances being applicable in each case.




5.4.5 The diameters of wires used are to be in accordancewith the recommendations of the manufacturer and are to bereported.

5.4.6 Test specimens from each butt weld assembly are tobe prepared and tested in accordance with the requirementsof Section 4 for two-run submerged-arc automatic welding.

5.4.7 The weld metal chemical analysis is to be reportedas in 4.6.9. The results of the analysis are not to exceed thelimit values specified in the standards or by the manufacturer,the narrower tolerances being applicable in each case.

5.5 Annual tests

5.5.1 Annual tests are to consist of at least the following:(a) Wires approved for manual welding or semi-automatic

welding or either of these combined with approval forautomatic multi-run welding:

one deposited metal test assembly prepared inaccordance with 5.2 using a wire of diameterwithin the approved range.

(b) Wire approved for automatic multi-run welding:one deposited metal test assembly prepared inaccordance with 5.3 using a wire of diameter asstated in (a).

(c) Wires approved for two-run automatic welding:one butt weld test assembly prepared in accordance with 5.4 using plates 20 to 25 mm inthickness or the maximum approved thickness.The diameter of wire used is to be reported.

■ Section 6Consumables for use in electro-slag and electro-gas welding

6.1 General

6.1.1 The requirements for the approval of consumablesused for electro-slag or electro-gas welding (includingconsumable nozzles, where applicable) are generally asdetailed in Section 4 for two-run submerged-arc weldingconsumables, except as otherwise detailed in this Section.

6.1.2 For each grade, approval may be restricted for usewith specific compositional types of steel. For Grades 1Y, 2Y,3Y, 4Y, 2Y40, 3Y40 and 4Y40 this will normally be in respectof the grain refining element content, and tests on niobiumgrain refined steel will normally qualify for use also on steelstreated with aluminium or vanadium or combinations of theseelements.

6.1.3 Superscript numbers are applied to the ‘Y’ of higherstrength steel consumables, e.g. 2Y1, to indicate the type ofparent steel for which approval is applicable as follows:Y1 approval Grade for higher strength steel is limited to

parent steel which has been treated only with aluminium.Y2 approval Grade for higher strength steel is appropriate

to niobium-treated steels, whether aluminium treated ornot. It also covers steels treated only with aluminium.

5.3.5 Test specimens from each test assembly are to beprepared and tested in accordance with the requirements ofSection 4 for multi-run submerged-arc automatic welding.

5.3.6 Low hydrogen approval tests are to be made ifrequired by 5.1.9.

5.3.7 At the discretion of LR, wires approved for semi-automatic welding in the downhand position may also beapproved without additional tests, for use in multi-run auto-matic welding.

5.4 Approval tests for two-run automatic welding

5.4.1 Approval tests for two-run automatic welding areto be carried out generally in accordance with the require-ments of Section 4, except as required by 5.4, using thetwo-run automatic welding technique for the preparation ofall test assemblies. Two butt weld test assemblies are to beprepared and tested using plates of the strength level forwhich approval is required. Each strength level requires sepa-rate approval.

5.4.2 Two butt weld test assemblies are to be preparedgenerally as detailed in 4.5 and 4.6 using plates 12 to 15 mmand 20 to 25 mm in thickness.

5.4.3 If approval is requested for welding plate thickerthan 25 mm, one assembly is to be prepared using platesapproximately 20 mm in thickness and the other using platesof the maximum thickness for which approval is requested.

5.4.4 The edge preparation of the test assemblies is tobe as shown in Fig. 11.5.1. Small deviations in edge prepa-ration may be allowed, if these form part of the consumable manufacturer’s recommendations. For assemblies usingplates over 25 mm in thickness, the edge preparation is to bereported for information.




60°

60°

60°

8 mm

8 mm

20–2

5 m

m

12–1

5mm

Fig. 11.5.1Normal edge preparation for two-run butt weld

test assemblies

6.3.2 The assembly is to be prepared and tested in accordance with 6.2 except that only the following tests arerequired:(a) One longitudinal tensile test.(b) One transverse tensile test.(c) Two bend tests.(d) Two sets of three Charpy V-notch impact tests; one set

with the notch at the centre of the weld (Position (1) inFig. 11.6.2), and one set with the notch in the weld metal2 mm from the fusion line (Position (2) in Fig.11.6.2).

(e) Chemical analysis.(f) One macro section.

6.3.3 Where a consumable or combination is approvedfor a range of steels with different specified minimum strengthlevels, steel of the highest strength level is to be used for thepreparation for the assembly required by 6.3.1.

6.1.4 Each strength level requires separate approvalinvolving the welding and testing of two butt weld assembliesof different thickness. The greater thickness will determine themaximum approved thickness.


6.2.1 Two butt weld test assemblies are to be prepared,one with plates 20 to 25 mm in thickness and the other withplates 35 to 40 mm in thickness. The steel used is not to be ofany higher grade (impact toughness) than that for whichapproval is required. The limitations of 6.1.2 need to be consid-ered in this Section. The chemical composition of the plate,including the content of grain refining elements, is to be reported.

6.2.2 The welding conditions and the edge preparationadopted are to be in accordance with the recommendationsof the manufacturer and are to be reported in detail. The manufacturer’s maximum recommended gap between platesis to be used in making the test assemblies.

6.2.3 It is recommended that the assemblies aresubjected to radiographic examination to identify any defectsbefore the preparation of any test specimens.

6.2.4 Test specimens as follows, and as shown inFig. 11.6.1, are to be prepared from each test assembly:(a) Two longitudinal tensile test specimens.(b) Two transverse tensile test specimens.(c) Two bend test specimens.(d) Two macro-sections.(e) Two sets of three impact test specimens notched in

accordance with Fig. 11.6.2.

6.2.5 The chemical analysis of the weld metal in eachassembly is to be determined and reported. This is to besupplied by the manufacturer and is to include the content ofall significant elements. The results of the analysis are not toexceed the limit values specified in the standards or by themanufacturer, the narrower tolerances being applicable ineach case.

6.2.6 The results of all transverse tensile and impact testsare to comply with the requirements given in Table 11.4.3 asappropriate. The position of fracture of the transverse tensiletest is to be reported. The Charpy V-notch impact testrequirements are as for the two-run technique in Table 11.4.3.

6.2.7 The results of all longitudinal tensile tests are tocomply with the requirements of Table 11.4.2.

6.2.8 The bend test specimens are to be in accordancewith 4.6.7 and Table 11.4.3. Each surface of the weld is to betested Fension.

6.3 Annual tests

6.3.1 Annual tests are to consist of at least one butt weldtest assembly using plate material 20 to 25 mm in thickness.




Transverse tensile


3450/06


Bend

Macro

Transverse tensile

Bend

Centre of weld

(2)

(1)Charpy tests(See Fig. 11.6.2)

Fig. 11.6.1Butt weld test assembly for electro-slag or

electro-gas welding

7.1.3 A wire and gas combination approved with anargon/carbon dioxide shielding gas where the carbon dioxidecontent is between 15-25 per cent is also approved for othercombinations of argon/carbon dioxide, provided the carbondioxide content is within the range 15-25 per cent. The rangeof approval is limited to ferritic consumables in solid wire, fluxcored and coated wire forms and subject to the agreement ofthe consumable manufacturer and LR.

7.1.4 Any unrecognised techniques or unusual combina-tions will be considered for approval subject to a testprogramme to be agreed based on the details of the techniqueand combination which are to be submitted in advance.

7.1.5 Where low hydrogen approval is required either byTable 11.7.1 or by the manufacturer, it should be noted thatthis will generally be achieved through separate testing of:(a) the backing material, and(b) the welding electrode or combination of wire-flux or

wire-gas.

7.1.6 The hydrogen potential of the backing material is tobe determined using the modified Gayley-Wooding methodwhich expresses the total hydrogen content as water byweight per cent. The qualifying levels are:

7.1.7 The sampling and approval of the combinationswithout the backing are to follow the general requirements ofSections 3, 4 or 5, as appropriate.

7.1.8 Combinations approved with multi-run technique(m, S and M) for normal and higher strength levels up to andincluding ‘Y’ are also considered suitable for welding steels inthe three strength levels below that for which they have beenapproved.

7.1.9 Combinations approved with multi-run technique(m, S and M) for strength levels Y40 to Y50, but excludingY47, are also considered suitable for welding steels in twostrength levels below that for which they have been approved.

7.1.10 Combinations approved with multi-run technique(m, S and M) for strength levels Y47, Y55 and above are alsoconsidered suitable for welding steels in only one strengthlevel below that for which they have been approved.

7.1.11 Combinations approved for the ‘A’ multi-run technique are not considered suitable for welding steels of anyother strength level with that technique.

■ Section 7Consumables for use in one-sidewelding with temporary backingmaterials

7.1 General

7.1.1 The requirements for approval of combinationsincluding temporary backing material, for use in one-side welding techniques, are dependent on the technique used andwhich basic technique it most closely follows. The following areprovided for:(a) Technique m – for manual electrode/backing combinations.(b) Technique S – for wire-gas/backing combinations used

with semi-automatic multi-run technique.(c) Technique M – for wire-flux or wire-gas in combination

with backing material (and maybe supplementary fillermaterials) used with an automatic multi-run technique.

(d) Technique A – as for M but using a procedure with a highheat input rate (large bead size relative to thicknesswelded). This would apply to welds made by four or lessruns in 20 mm thickness, or eight or less runs in 35 mm.

7.1.2 For technique m, S or M, a single butt weld is to bemade in plate of 20–25 mm thickness. For technique A, twobutt welds are to be made, one in plate of the maximum thickness recommended by the manufacturer, the other inplate of approximately half the thickness of the first. Usuallythis will involve thicknesses in the region of 35–40 mm and 20–25 mm respectively.




To qualify as: H20 g/100g sample

H15 0,5H10 0,3H5 0,2

(1) In the centre of the weld metal

(2) In the weld metal, 2 mm from the fusion line

2 mm 2 mm

Fig. 11.6.2Position of Charpy V-notch impact test specimens

7.2.3 The edge preparation and welding conditions areto be in accordance with the recommendations of themanufacturers.

7.2.4 Test specimens are to be prepared as shown in Fig. 11.7.1 and Fig. 11.7.2(a):(a) One longitudinal tensile test specimen (from the centre

of the weld).(b) Two transverse tensile specimens.(c) Two bend test specimens, one with the face in tension,

the other with the root in tension.(d) One macrosection.(e) Two sets of three Charpy impact test specimens

positioned and notched in accordance with Fig.11.7.2(a).

7.2.5 The results of all transverse tensile, bend and impacttests are to comply with the requirements in Table 11.3.3 for mand S technique, and Table 11.4.3 for M technique. The position of fracture of the transverse tensile test is to bereported. The appearance of the bend test specimens is to bein accordance with 3.3.13.

7.2.6 The results of all longitudinal tensile tests are tocomply with the requirements in Table 11.3.2.

7.2.7 Low hydrogen approval is required in accordancewith Table 11.7.1.

7.2.8 Chemical analyses are to be made and reportedfrom positions corresponding to the weld metal in the upperand lower Charpy specimens of the downhand butt weld.These are to be supplied by the manufacturer and are toinclude the content of all significant elements. The results ofthe analysis are not to exceed the limit values specified in thestandards or by the manufacturer, the narrower tolerancesbeing applicable in each case.

7.2 Approval tests for manual (m), semi-automatic(S) and automatic multi-run (M) techniques

7.2.1 For each position to be approved, one butt weldassembly is to be prepared using plates of 20–25 mm thickness as shown in Fig. 11.7.1. The grade of plate used isto be no higher in toughness than that for which approval isrequired. The strength is to be appropriate to the grade forwhich welding approval is requested.

7.2.2 The thickness of test assembly is to be 50 mm forY47 base material.




Table 11.7.1 Minimum low hydrogen approval requirements for one-side welding with combinations includingtemporary backing material

‘H’ grade for ‘H’ grade for ‘H’ grade forApproval grades m and S M A

techniques technique technique

1 (1N), 2 (2N), 3 (3N) NR NR NR 1Y, 2Y, 3Y, 4Y H15 (see Note 2) NR NR 2Y40 to 5Y40 H15 H15 NR 3Y47 H10 H10 H15

3Y42 to 5Y42 H10 H10 H15 3Y46 to 5Y46 H10 H10 H15 3Y50 to 5Y50 H10 H10 H10 3Y55 to 5Y55 H5 H5 H10 3Y62 to 5Y62 H5 H5 H5 3Y69 to 5Y69 H5 H5 H5

11/2 Ni H15 H15 NR 31/2 Ni H15 H15 NR 5 Ni (see Note 3) NR NR NR 9 Ni (see Note 3) NR NR NR

NOTES 1. NR – Not required. Approval may be obtained when requested.2. Optional in this case. If low hydrogen approval is not obtained, there is a limitation on the carbon equivalent of the steel which is

permitted to be welded. 3. Assumes the use of an austenitic, non-transformable, filler material.

Temporary backing

Two sets of Charpy specimensfrom thinner assembly.

Three sets from thicker assembly

See Fig. 11.7.2

3450/08

Fig. 11.7.1Butt weld test assembly and specimens for all

techniques




7.3 Approval tests for high heat input automatic(A) techniques

7.3.1 Two butt weld assemblies are to be prepared,usually one of 35–40 mm thickness, the other 20–25 mm, asshown in Fig. 11.7.1, noting that in the thinner assembly onlytwo sets of Charpy specimens are required. The grade ofplates used is to be no higher in toughness than that for whichapproval is required. The strength is to be appropriate to thegrade for which welding approval is requested.

7.3.2 For Y47 grade, the thicker assembly is to beprepared from the maximum thickness for which approval isrequired, and the thinner assembly is to be prepared from 50 mm thickness. Where approval is required for 50 mmthickness, only one assembly from that thickness is required.

7.3.3 The edge preparation and welding conditions areto be in accordance with the manufacturer’s recommenda-tions, and are to be reported to LR.

7.3.4 Test specimens as follows are to be prepared asshown in Fig. 11.7.1 and Figs. 11.7.2(a) and (b):(a) One longitudinal tensile test specimen (from centre of

weld).(b) Two transverse tensile test specimens.(c) Two bend test specimens.(d) One macro-section.(e) From assembly 20 to 25 mm thick, two sets of three

impact test specimens positioned and notched in accordance with Fig. 11.7.2(a).

(f) From assembly 35 to 40 mm thick, three sets of threeimpact test specimens positioned and notched in accordance with Fig. 11.7.2(b).

(g) From assembly of thickness 50 mm or more, three setsof three impact test specimens positioned and notchedin accordance with Fig. 11.7.2(b). The second set positioned in the mid-thickness of test assembly.The bend specimens are to be tested, one with the facein tension, the other with the root in tension.

7.3.5 The results of all transverse tensile, bend andimpact tests are to comply with the requirements of Table 11.4.3. The appearance of the bend test specimens isto be in accordance with 3.3.13. The Charpy V-notch impacttest requirements are as for the two-run technique in Table 11.4.3.

7.3.6 The results of all longitudinal tensile tests are tocomply with the requirements in Table 11.3.2, except that forGrades 1Y, 2Y and 3Y the tensile strength is to be not lessthan 490 N/mm2.

7.3.7 Low hydrogen approval is required in accordancewith Table 11.7.1.

7.3.8 Chemical analyses are to be made and reportedfrom positions corresponding to the weld metal in the uppermost and lowest Charpy specimens in the thicker plateweld. This is to be supplied by the manufacturer and is toinclude the content of all significant elements. The results ofthe analysis are not to exceed the limit values specified in thestandards or by the manufacturer, the narrower tolerancesbeing applicable in each case.

7.4 Annual tests

7.4.1 Annual tests are to consist of, at least, one buttweld test assembly, for each technique approved, usingplates of 20 to 25 mm thickness.

7.4.2 The assembly is to be prepared and tested inaccordance with 7.2 or 7.3, as appropriate, except that onlythe following tests are required:(a) One longitudinal tensile test (from centre of weld).(b) One transverse tensile test.(c) Two bend tests.(d) One set of three impact tests taken from the root of the

weld and the specimens notched in accordance withFig. 11.7.2.

(e) Chemical analysis (one only).

■ Section 8Consumables for weldingaustenitic and duplex stainlesssteels

8.1 General

8.1.1 Tests for the approval of consumables intended forwelding the austenitic and duplex stainless steels detailed inCh 3,7 are to be carried out generally in accordance with theSection (3, 4, 5, 6 or 7) relevant to the type of consumable orcombination.

(a)

(b)

2 mm

2 mm

10 m

m 10 m

m10

mm

35–4

0mm

10 m

m

2 mm

2 mm

10 m

m

20–2

5 m

m

Fig. 11.7.2Position of Charpy V-notch impact tests for

one-side automatic welding

A – as for M but using a procedure with a high heatinput rate (large bead size relative to thicknesswelded). This would apply to welds made byfour or less runs in 20 mm thickness, or eight orless runs in 35 mm.

8.2 Deposited metal test assemblies

8.2.1 Where the relevant Section requires deposited metalassemblies to be made and tested, the plates used must beeither of the type for which approval is required or of normalstrength carbon, or carbon-manganese steel with the preparededges built up with stainless steel weld metal and finished witha layer of weld metal from the consumable to be approved.

8.2.2 The chemical analysis of the deposited weld metal isto be reported, including all significant elements. The elementsreported will be dependent on the type of stainless steel forwhich approval of the consumables is requested. Any unusualweld metal compositions will have to be justified in respect ofthe particular approval requested. This is to be supplied by themanufacturer and is to include the content of all significantelements. The results of the analysis are not to exceed the limitvalues specified in the standards or by the manufacturer, thenarrower tolerances being applicable in each case.

8.2.3 The results of all tensile and notch impact tests areto comply with the requirements given in Table 11.8.1 asappropriate.

8.2.4 The ferrite content in the last weld run from eachdeposited metal assembly is to be determined by physical ormetallographic means, and reported, indicating the methodof determination.

8.1.2 Approval will be indicated by the grade or gradesof parent stainless steel for which the consumable or combi-nation is approved.

8.1.3 Where a shielding gas is employed, separate approvalwill be required for each specific shielding gas composition.

8.1.4 Consumables for welding the austenitic stainlesssteels and the duplex stainless steels to carbon or carbon-manganese steels will be approved in a similar manner. Parentplate used for the butt and fillet weld test assemblies will becarbon or carbon-manganese steel with either austeniticstainless steel or duplex stainless steel, as appropriate.Approval will be indicated by ‘SS/CMn’ and ‘Dup/CMn’respectively, however, no buttering of test assembly plates isallowed for these two approvals.

8.1.5 Separate approval will be given for welding chemical and cryogenic applications. For chemical use,evidence of relevant corrosion resistance will be required.Charpy impact toughness tests will be required for all uses,but for cryogenic use the Charpy impact toughness requirements are more severe.

8.1.6 The welding technique will be indicated in theapproval grading by a letter:

m – for manual SMAW or GTAW welding.S – for wire-gas combinations used with a semi-

automatic multi-run technique.M – for wire-flux or wire-gas combinations used with

an automatic multi-run technique.T – for wire-flux or wire-gas combinations used with

an automatic two-run technique.




Charpy V-notch impact tests0,2% proof 1% proof Tensile Elongation

Grade stress stress strength on Chemical Cryogenic AverageN/mm2 N/mm2 N/mm2 50 mm test test energy

minimum minimum minimum % minimum temperature temperature See Note 1°C °C J minimum

304L 270 310 500 25 –20 –196 29304LN 305 345 530 22 –20 –196 29316L 270 310 500 22 –20 –196 29

316LN 305 345 530 22 –20 –196 29317L 305 345 530 22 –20 –196 29

317LN 340 380 570 22 –20 –196 29321 290 330 550 22 –20 –196 29347 290 330 550 22 –20 –196 29

S 31254 370 410 650 22 –20 –196 29N 08904 270 310 500 22 –20 –196 29

SS/CMn 270 310 500 22 –20 –60 29

S 31260 485 525 690 20 –20 40S 31803 450 490 620 25 –20 40S 32550 550 590 760 15 –20 see Note 2 40S 32750 550 590 800 15 –20 40S 32760 550 590 750 25 –20 40

Dup/CMn 270 310 500 22 –20 see Note 2 40

NOTES1. Energy values from individual impact test specimens are to comply with 1.4.3.2. Approval for cryogenic applications is to be obtained at the procedure approval stage.

Table 11.8.1 Requirements for deposited metal tests (manual, semi-automatic and automatic multi-run techniques)

}


8.3.1 Where the relevant Section requires butt weld assemblies to be made and tested, the plates used are to beeither of the type for which approval is required or of steel havingstrength and ductility within the range specified for the grade tobe approved. In the latter case, provided the consumable ismetallurgically compatible with the base material to be used, theprepared edges are to be built up with a layer of weld metalbefore final machining of the weld preparation.

8.3.2 The results of transverse tensile, notch impact andbend tests are to comply with the requirements of Table 11.8.2as appropriate. The position of fracture is to be reported to LR.

8.3.3 The ferrite content at the centre of the weld metal ineach butt weld assembly is to be determined by physical ormetallographic means, and meet the requirements in Table 11.8.2. The method of determination is to be reported.

8.3.4 For austenitic and duplex stainless steel approvals(except for types 304L, 316L, 321 and 347), an appropriatesample from each butt weld assembly is to be submitted to thecorrosion testing provided in ASTM G48, Method ‘C’. Theresults are to be reported so as to allow confirmation of themaximum acceptable pitting corrosion resistance temperature.This will be part of the approval grading and will be set at 5°Cintervals. The minimum pitting corrosion temperature would notbe expected to be less than 20°C.

8.4 Fillet weld test assemblies

8.4.1 Where the relevant Section requires fillet weldassemblies to be made and tested, the plates used must beeither of the type for which approval is required or of steelhaving strength and ductility within the range specified for thegrade to be approved. In the latter case, the surfaces on whichthe fillet weld beads are to be deposited are to be cut back bymachining and then built up to original dimensions with weldmetal from the consumable to be approved.

8.4.2 The ferrite content at the centre of the weld metal ineach fillet weld bead of each assembly is to be determinedfrom the centre macro-section by physical or metallographicmeans, and reported. The method of determination is also tobe reported to LR.

8.4.3 Where approval is sought for fillet welding only,corrosion testing is to be carried out in accordance with 8.3.4from a sample taken from the deposited metal test assembly.

8.5 Annual tests

8.5.1 Annual tests are to be carried out as required by therelevant Section appropriate to the type of consumable andwelding technique. The tests are to include a weld ferritecontent in accordance with 8.2.4 or 8.3.3 as appropriate.

8.5.2 The results of all tests are to comply with therequirements given in Table 11.8.1 and Table 11.8.2 as appropriate.




Charpy V-notch impact testsTensile Bend test Weld

Grade strength ratio: ferrite Chemical Cryogenic AverageN/mm2 content test test energy

minimum % temperature temperature (see Note 1)°C °C J minimum

304L 500 3 4–12 –20 –196 27304LN 530 3 4–12 –20 –196 27316L 500 3 4–12 –20 –196 27

316LN 530 3 4–12 –20 –196 27317L 530 3 4–12 –20 –196 27

317LN 570 3 4–12 –20 –196 27321 550 3 4–12 –20 –196 27347 550 3 4–12 –20 –196 27

S 31254 650 3 (see Note 2) –20 –196 27N 08904 500 3 (see Note 2) –20 –196 27

SS/CMn 500 3 4–12 –20 –60 27

S 31260 690 4 35–65 –20 40S 31803 620 3 35–65 –20 40S 32550 760 6 35–65 –20 (see Note 3) 40S 32750 800 6 35–65 –20 40S 32760 750 6 35–65 –20 40

Dup/CMn 500 3 (see Note 2) –20 (see Note 3) 40

NOTES1. Energy values from individual impact test specimens are to comply with 1.4.3.2. To be reported for special consideration.3. Approval for cryogenic applications is to be obtained at the procedure approval stage.

Dt

Table 11.8.2 Requirements for butt weld tests (all techniques)

}

9.1.5 Approval granted using the multi-run technique for aspecific filler/electrode wire with a gas in one of the groups listedin Table 11.9.2 will extend to any other gas compositions withinthat same group, provided that the gas composition is withinthe range recommended by the consumable manufacturer,subject to agreement with LR.

9.1.6 Approval granted for the two-run technique will befor a specific shielding gas composition; additional tests maybe required if a change in shielding gas composition is sought.

9.1.7 On completion of welding, assemblies are to beallowed to cool naturally to ambient temperature. Welded testassemblies and test specimens are not to be subjected to any heat treatment after welding except for the alloy Grades 6005A, 6061 and 6082. These are to be allowed tonaturally age at ambient temperature for a period of 72 hoursfrom the completion of welding, before testing is carried out.A second solution heat treatment is not permitted.

9.1.8 All butt test assemblies are to be subjected to bothradiographic and visual examination and imperfections suchas lack of fusion, lack of penetration, cavities, inclusions,pores and cracks assessed in accordance with IntermediateLevel C of ISO 10042, aided where necessary by dye penetrant and ultrasonic examination.

9.1.9 Fillet weld test assemblies and macro-sections areto be visually examined for imperfections, such as lack offusion, lack of penetration, cavities, inclusions, pores andcracks, in accordance with Intermediate Level C of ISO 10042,aided where necessary by radiographic and dye penetrantexamination.

9.2 Approval tests for manual, semi-automaticand automatic multi-run techniques

9.2.1 Plate of the corresponding type of aluminium alloyand of appropriate thickness is to be used for the preparationof the weld test assemblies.

■ Section 9Consumables for weldingaluminium alloys

9.1 General

9.1.1 Tests for the approval of consumables intended forwelding the aluminium alloys detailed in Chapter 8 are to becarried out generally in accordance with the requirements ofSections 1, 2 and 5, except as otherwise detailed in thisSection.

9.1.2 Approval will be indicated by the grade shown inTable 11.9.1. Plate of the corresponding type of aluminiumalloy and of appropriate thickness is to be used for the prepa-ration of the weld test assemblies, and may be of any temperlisted in LR Rules.

9.1.3 The welding technique will be indicated in theapproval grading by a letter:

m – manual multi-run welding (GTAW),S – semi-automatic multi-run welding (GMAW),M – automatic multi-run welding (GTAW or GMAW),T – automatic two-run welding (GMAW).

9.1.4 The compositions of the shielding gas and thefiller/electrode wire are to be reported.




Table 11.9.1 Requirements for butt weld tests

Consumable Tensile Bend testApproval Base material strength ratio

Grade used for the test N/mm2

(see Note 1) minimum

LR RA/LR WA 5754 190 3

LR RB/LR WB 5086 240 6

LR RC1/LR WC1 5083 275 6

LR RC2/LR WC2 5383 or 5456 290 6(see Note 2)

LR RC3/LR WC3 5059 330 6(see Note 2)

LR RD/LR WD 6005A 170 6(see Note 4) 6061 170 6

6082 170 6

NOTES1. The prefixes ‘R’ and ‘W’ indicate ‘rod’ form (for Gas Tungsten

Arc Welding (GTAW)) or ‘wire’ form (for Gas Metal Arc Welding(GMAW) and GTAW).

2. Approval of grade LR RC2/LR WC2 confers approval of 5383,5456 and 5083 base material grade.

3. Approval of grade LR RC3/LR WC3 confers approval of 5059,5383, 5456 and 5083 base material grades.

4. Approval of grade LR RD/LR WD confers approval of 6005A,6061 and 6082 base material grades.

Dt

Gas composition (Vol. %)Group (see Note)

Helium Argon

I-1 – 100

I-2 100 –

I-3 >0 ≤33 Remainder



S Special gas

NOTEGases of other composition (mixed gases) or special purity maybe considered as special gases and will require separate approvaltests.

Table 11.9.2 Shielding gas compositions


9.4.1 Plate of the corresponding type of aluminium alloyand of an appropriate thickness is to be used for the preparation of the test assemblies.

9.4.2 In order to ensure sound and representative welds,it is essential that test assemblies are cleaned and degreasedprior to welding. Assemblies as shown in Fig. 11.9.2 are to beprepared for each welding position (downhand, horizontal-vertical, vertical-upward, vertical-downward, and overhead) forwhich the consumable is recommended by the manufacturer;except that consumables satisfying the requirements fordownhand and vertical-upward positions will be considered asalso complying with the requirements for the horizontal-verticalposition. Any wire diameter(s) to be approved may be used.

9.2.2 The welding parameters are to be within the rangerecommended by the manufacturer and are to be reported.

9.2.3 Welded assemblies are to be prepared and testedin accordance with 9.3, 9.4 and 9.5.

9.3 Deposited metal test assembly

9.3.1 One assembly is to be prepared in the downhandposition as shown in Fig. 11.9.1.

9.3.2 The chemical composition of the plate used for theassembly is to be compatible with the weld metal.

9.3.3 The thickness of the plate used, and the length ofthe assembly, are to be appropriate to the welding process.The plate thickness is to be not less than 12 mm.

9.3.4 For the approval of filler wire/gas and electrodewire/gas combinations for manual or semi-automatic weldingby GTAW or GMAW, one test assembly is to be welded usingany size of wire within the range for which approval is sought.

9.3.5 For automatic multi-run approval, one test assemblyis to be welded by the respective process using the recom-mended diameter of wire.

9.3.6 The weld metal is to be deposited in multi-run layersin accordance with normal practice. The direction of depositionof each layer is to alternate from each end of the plate.

9.3.7 The deposited weld metal in the assembly is to beanalysed and reported including the contents of all significantelements. The elements reported will be dependent on thetype of aluminium alloy for which approval of the consumablesis requested. The results of the analysis are not to exceed thelimit values specified in the standards or by the manufacturer,the narrower tolerances being applicable in each case.




Root bend

35º 35º

35º 35º

35º 35º

Face bend

Transverse tensile

Root bend

Face bend

Transverse tensile

30 mm

10 -12 mm

10 -12 mm

30 mm

35 mm

30 mm

350 mm min

350

mm

min

30 mm

35 mm

OR

5787/02

2 to 3 mm

Fig. 11.9.2Butt weld test assembly

(positional, multi-run technique)

t

t

Depositthickness30 mm minimum

Depositedweld metal

Sampling position

Plate thickness12-25 mm

Tack weld

15 mm

5787/01


9.4.8 The bend test specimens are to be bent around aformer having a diameter not more than the number of timesthe thickness of the test specimen, as shown in Table 11.9.1,and can be considered as complying with the requirementsif, after bending to an angle of not less than 180°, no crack orother open defect exceeding 3 mm in length can be seen onthe outer surface. Flaws appearing at the corners of a testspecimen may be ignored.

9.4.9 In order to obtain uniform bending of the bend testspecimens, it is recommended that the wrap-around orguided bend test using a roller method is employed.

9.5 Fillet weld test assembly

9.5.1 When approval is being sought for both butt andfillet welding, one assembly is to be prepared and welded inthe horizontal-vertical position and tested in accordance withthe appropriate requirements of 3.5, except that the platesare to be of an aluminium alloy compatible with the weldmetal, that no hardness tests are required and that for automatic multi-run approval only one fillet weld bead is to bemade using the recommended wire diameter. In this case, thebead size is to be as large as the maximum single bead sizerecommended by the manufacturer for fillet welding.

9.5.2 When approval is being sought for fillet weldingonly, one assembly is to be prepared and welded in eachposition for which approval is sought, and tested as detailedin 9.5.1.

9.5.3 The results of examination of the macro-specimensand the fractured fillet welds are to be reported in accordancewith 3.5.4 and 3.5.6. Imperfections are to be assessed inaccordance with 9.1.9.

9.6 Approval tests for two-run technique

9.6.1 Two butt weld test assemblies are to be preparedusing the following plate thicknesses:(a) one with the maximum thickness for which approval is

requested; and(b) one with a thickness approximately one half to two thirds

that of the maximum thickness.

9.7 Butt weld test assemblies (two-run technique)

9.7.1 The plates used are to be of the aluminium alloyappropriate to the approval required as shown in Table 11.9.1.The composition of the plate material is to be within the rangespecified for that alloy in Table 8.1.2 in Chapter 8 and is to bereported including all significant elements.

9.7.2 The wire diameter, edge preparation, weldingcurrent, arc voltage and travel speed are to be in accordancewith the manufacturer’s recommendations and are to bereported.

9.7.3 Each butt weld is to be made in two runs, one fromeach side. After completion of the first run, the assembly is tobe left in still air until it has cooled to less than 50°C.

9.4.3 One assembly, as shown in Fig. 11.9.3, is to beprepared for welding in the downhand position. The assemblyis to be welded using, for the first run, wire of the smallestdiameter recommended by the manufacturer and, for theremaining runs, wire of the largest diameter to be approved.

9.4.4 The welding conditions are to be in accordancewith the recommendations of the manufacturer and are to bereported in detail.

9.4.5 The welded assemblies are to be subjected toNDE. Imperfections are to be assessed in accordance with9.1.8.

9.4.6 The test specimens are to be taken from thewelded assemblies as shown in Fig. 11.9.2 and Fig. 11.9.3.For each assembly they are to comprise:• 2 transverse tensile specimens;• 2 face bend specimens; and• 2 root bend specimens.

9.4.7 All tensile test specimens are to have a tensilestrength not less than the respective value shown in Table 11.9.1. The position of each fracture is to be reported.




Root bend

35º 35º

Face bend

Transverse tensile

Root bend

Face bend

Transverse tensile

30 mm

20 - 25 mm

30 mm

35 mm

30 mm

350 mm min

2 to 3 mm

350

mm

min

30 mm

35 mm

5787/03

Fig. 11.9.3Butt weld test assembly

(downhand, multi-run technique)

9.7.4 The welded assemblies are to be subjected toNDE. Imperfections are to be assessed in accordance with9.1.8.

9.7.5 The test specimens as shown in Fig. 11.9.4 are tobe prepared from each test assembly. The edges of thediscards are to be polished and etched, and must showcomplete fusion and inter-run penetration of the welds. Eachcut in the assembly is also to be examined to confirm thatcomplete fusion and penetration have been achieved.

9.7.6 The results of the transverse tensile tests are to beas in 9.4.7 and of the bend tests as in 9.4.8. The position ofthe fracture in each transverse tensile specimen is to bereported.

9.8 Annual tests

9.8.1 Annual tests are to consist of the following:(a) for combinations approved for the multi-run technique,

one deposited metal assembly in 9.3 and one downhandbutt assembly in 9.4;

(b) for combinations approved for the two-run technique,one butt weld assembly in plate material of thicknessequal to one half to two thirds that of the maximum thickness approved.

9.8.2 For the automatic two-run technique, one butt weldassembly is to be prepared and tested in accordance with9.7.




Transverse tensile

Bend

Bend

Transverse tensile

350 mm min

350

mm

min

5787/04

35 mm

35 mm

30 mm

30 mm

Fig. 11.9.4Butt weld test assembly (two-run technique)

Section

1 General qualification requirements

2 Welding procedure qualification tests for steels

3 Specific requirements for stainless steels

4 Welding procedure tests for non-ferrous alloys

5 Welder qualification tests

6 Qualification of friction stir welding of alluminium alloys

■ Section 1General qualification requirements

1.1 General

1.1.1 This Section applies to all welding qualifications andtests required to be performed in the course of new construc-tion, conversions, modifications or repairs made on ships,other marine structures and their associated pressure vessels,machinery and equipment.

1.1.2 These Rules also apply to all welding work relatedto other applications for which Lloyd’s Register (hereinafterreferred to as LR) have issued Rules or have an interest.

1.1.3 It is the responsibility of the manufacturer to ensurecompliance with all aspects of these Rules. All deviations areto be recorded as non-compliances and brought to the attention of the Surveyor along with the corrective actionstaken. Failure to do this is considered to render the weldingtests as not complying with the Rules.

1.1.4 Welding tests are to be performed under survey atthe manufacturer’s works. Welding procedure qualificationtests and welder qualifications tests are to be performed andapproved prior to commencement of fabrication or construction.

1.1.5 Weld procedure tests made in accordance with EN,ISO, JIS, ASME or AWS may be considered for acceptanceprovided that, as a minimum, they are equivalent to and meetthe technical intent of these Rules to the satisfaction of theSurveyor.

1.1.6 Welding tests that have previously been carried outmay be considered for acceptance, provided that they havebeen supervised by an independent body acceptable to LRand the Surveyor is satisfied with the authenticity of suchtests.

1.1.7 The responsibility for the performance of the weldtests rests with the manufacturer. Aspects of the weldingtests, such as mechanical testing, non-destructive testing andheat treatment, may be subcontracted by the manufacturerprovided that the subcontractor performs the work under thetechnical control and direction of the manufacturer, and this isagreed with the Surveyor prior to commencing the work.

1.1.8 In these Rules, the term ‘manufacturer’ is consideredto include any firm or organisation that performs welding andis considered to be the shipbuilder, or construction firm, orfabricator, or material manufacturer.

1.2 Design

1.2.1 Welding procedure qualification tests are required togive assurance that construction welds made in accordancewith the approved plans or the approved design have accept-able properties. It is the manufacturer’s responsibility to establish and document whether a procedure is suitable for aparticular application.

1.2.2 The requirements relate to mechanical properties ofthe weld and heat affected zone, however, other tests may berequired on certain materials, for example, corrosion or fatiguetests, in order to ensure suitability for the proposed application.

1.3 Materials

1.3.1 Materials used for testing are to be of the samegrade, type and from the same manufacturing process asthose to be used for construction, unless prior agreement isobtained from the Surveyor. Such agreements will only applyon a case-by-case basis.

1.3.2 All materials used for testing are to be suitablymarked and identifiable to the original manufacturer’s materialcertificate.

1.4 Performance of welding tests

1.4.1 All welding and subsequent testing is to be performedin accordance with the requirements of this Chapter.

1.4.2 The manufacturer is responsible for monitoring thetests and for recording all the welding variables as specified in2.2 and for compiling all the non-destructive examination(NDE) reports and mechanical test records for submission tothe Surveyor.

1.4.3 The laboratory or testing establishment used to perform the tests is to have the necessary equipment, main-tained in good order and suitably calibrated. The Surveyor isto be satisfied that the laboratory personnel have the appro-priate skills and are appropriately qualified in accordance withCh 2,1.2.1.


Chapter 12Section 1


Welding Qualifications

■ Section 2Welding procedure qualificationtests for steels

2.1 General

2.1.1 The requirements of this Section relate to welding procedure test requirements of carbon, carbon-manganesesteels and low alloys steels. Additional requirements foraustenitic and austenitic/ferritic duplex stainless steels, aluminiumand copper alloys are specified in Sections 3 and 4 respec-tively.

2.1.2 Prior to performing the welding procedure qualifica-tion test, the manufacturer is to present to the Surveyor a preliminary Welding Procedure Specification (pWPS) detailingthe welding processes, positions, joint types, materials andheat treatments to be performed during the test. The pWPS isto be presented for information prior to commencing the test.

2.1.3 The type and extent of testing to be applied to eachwelding procedure test is to be in accordance with subsequentSections of this Chapter.

2.1.4 For the welding procedure approval, the weldingprocedure qualification tests given in this Section are to becarried out with satisfactory results. Welding procedure specifications are to refer to the test results achieved duringwelding procedure qualification testing.

2.2 Welding variables

2.2.1 In order that the conditions of the qualification testmay be applied to production welding operations, the appropriatevariables are to be recorded by the manufacturer during welding and testing from the following list:(a) The unique qualification reference number and the date

of welding;(b) The material type, grade, product form, dimensions and

identification;(c) Welding process(es), including tack welds;(d) Joint type, dimensions and surface condition;(e) Welding position(s);(f) Welding technique(s), weaving, multiple electrodes, etc;(g) Welding consumables including fluxes, shielding gases,

etc;(h) Control of consumables, baking or drying conditions,

etc;(j) Welding parameters, current, voltages, travel speeds,

etc;(k) Number and sequence of weld runs;(l) Backing materials including any backing gas;(m) Preheats and interpass temperatures;(n) Methods used for cleaning and inspection of root

deposits;(o) Post-weld heat treatment, temperature and cycle times;(p) Special weld profiling requirements.

2.2.2 Other variables may need to be recorded dependingon the particular welding process or application and are to beagreed with the Surveyor, for example the peak and base currentand cycle times for pulse welding, electrode type and nozzlesize for GTAW welding, etc.

2.3 Steel test assemblies

2.3.1 Tests are to be performed using the welding processand positions anticipated for actual construction. The weldtest assemblies are to be representative of construction conditions and are to be welded in the same manner asintended for the actual production welds. Where pre-fabricationprimers are used in the shipyard, these are to be included inthe test assemblies.

2.3.2 For plate tests, the direction of plate rolling relativeto the weld direction is to be considered. Where the materialused for the test requires longitudinal impact tests, the platerolling direction is to be perpendicular to the weld directionand for material which requires impact testing in the transversedirection, the rolling direction is to be parallel to the weld direction. For weld tests intended for liquefied gas storage orcargo tanks and associated process pressure vessels, thedirection of plate rolling is to be parallel to the weld direction inall cases.

2.3.3 Typical test assemblies are shown in Fig. 12.2.1(a) to(c). These are a minimum requirement to permit the removal ofall the necessary mechanical test specimens. Where impacttests or other toughness tests are required, the total width isnot to be less than 8 times the material thickness of the thickermaterial being joined.


Welding Qualifications Chapter 12Section 2

LLOYD’S REGISTER2

L

D (discard)

t (thickness)

Rolling direction for plates with longitudinalCharpys

Rolling direction for plates with transverseCharpys

W2

W2

4607/25

Welding Processes L (min) W (min) D (min) mm mm mmManual/Semi-automatic 350 300 50Automatic 1000 400 75

Fig. 12.2.1(a) Butt weld test assembly in plate

2.3.4 Welding procedure test assemblies are to be weldedseparately from production welds and are to be marked withthe unique test identification number. The individual pieces ofthe test assembly may be held together to maintain their relative joint conditions by means of suitable tack welds,clamps or strongbacks.

2.3.5 Welding of the test assemblies and testing of testspecimens is to be monitored by the Surveyor.

2.3.6 The test assembly is to be placed in one of thewelding positions shown in Fig. 12.2.2(a) to (d), as specified inthe test Welding Procedure Specification (pWPS) and thespecified level of preheat applied prior to the start of welding.

2.3.7 Designations for equivalent welding positionsshown by different standards are shown in Table 12.2.1.

2.4 Welding of steel test assemblies

2.4.1 Welding of the test assembly is to be carried out inaccordance with the agreed pWPS. Where, during theprogress of the test, it is found necessary to change the conditions specified on the pWPS, this is to be brought to theattention of the Surveyor. If agreed, the test may be permittedto continue with the new conditions and these are to berecorded.


Chapter 12Section 2



D

LL

L = 150 mm minimumD = Outside diameter

D

W

L

4607/26

Macro

Macro

Fracture

Macro

Fracture

Welding Processes L (min) W (min) D (min) mm mm mmManual/Semi-automatic 350 300 50Automatic 1000 300 75

W2

Fig. 12.2.1(c) Fillet weld test assembly in plate

Fig. 12.2.1(b) Butt weld test assembly in pipe

Plate butt welds

Flat

Horizontal

Vertical, weld up

Vertical, weld down

Overhead

Pipe butt welds

Pipe horizontal,rotated, weld horizontal

Pipe vertical, notrotated, weld horizontal

Pipe horizontal, notrotated, weld flat,vertical and overhead

Pipe inclination fixed,not rotated

Plate fillet welds

Flat

Horizontal

Vertical up

Vertical down

Overhead

Pipe fillet welds

Flat, pipe rotated

Horizontal, pipe fixed

Horizontal, piperotated

Overhead, pipe fixed

Multiple, pipe fixed

D

X

Vu

Vd

O

D

X

D+Vu+OD+Vd+O

45°

D

X

Vu

Vd

O

D

X

D

O

D+Vu+OD+Vd+O

ISO 6947

PA

PC

PF

PG

PE

PA

PC

PFPG

H-L045J-L045

PA

PB

PF

PG

PD

PA

PB

PB

PD

PFPG

AWS

1G

2G

3G

3G

4G

1G

2G

5G

6G

1F

2F

3F

3F

4F

1FR

2F

2FR

4F

5F

Table 12.2.1 Equivalent designations of weldingpositions

Weld positionStandard



LLOYD’S REGISTER4

D Position

X Position

Axis@ 45° Position

Pipe or tube vertical andnot rotated during weldingWeld horizontal

Pipe horizontal and rotatedWeld flat

Pipe or tube horizontal,not rotated during weldingWeld flat, vertical and overhead

Pipe inclination fixed and notrotated during welding

Horizontal

2665/05

45°

D + Vu + OorD + Vd + OPosition

Position of pipes and welds for qualification weld test assemblies

Fig. 12.2.2(b) Pipe butt weld test positions

Flat(Plates horizontal)

Horizontal(Plates vertical)

Vertical(Plates vertical)

Overhead(Plates horizontal) 2665/06

D Position

X Position

Vu & Vd Positions

O Position

Position of test plates for plate assemblies

Fig. 12.2.2(a) Plate butt weld test positions

2.4.2 Where the production work requires welding overtack welds, the test is to simulate this condition and the tackwelds are to be included in the inspection length of the testweld and their position recorded.

2.4.3 For manual and semi-automatic welding processes,weld stops and re-starts are to be included in the inspectionlength of the test weld.

2.4.4 Fillet weld test assemblies are welded on one sideonly.

2.4.5 Where the construction welding is predominately filletwelding, in addition to the butt weld qualification test, a filletweld qualification test is to be performed to confirm thatacceptable weld quality is achieved.

2.5 Non-destructive examination (NDE)

2.5.1 On completion of welding, prior to sectioning formechanical tests, the inspection length of the test assembly isto be subjected to both visual examination and surface crackdetection.

2.5.2 Butt weld assemblies are also to be subjected toradiographic or ultrasonic examination over the whole inspectionlength of the weld.

2.5.3 For welds in steels with specified yield strength upto 400 N/mm2, and with carbon equivalent less than or equalto 0,41 per cent, NDE may be performed as soon as the testassembly has cooled to ambient temperature. For other steels,NDE is to be delayed for a period of at least 48 hours after thetest assembly has cooled to ambient temperature.

2.5.4 Where post-weld heat treatment is required, NDE isto be performed after the heat treatment is complete.

2.5.5 All NDEs are to be carried out in accordance with therequirements of Ch 1,5. Assessment of results is to be inaccordance with ISO 5817 Level B except for excess convexityand excess throat thickness where Level C will apply. Linearporosity is not permitted.


Chapter 12Section 2



Throat of weldvertical Axis of weld

horizontal

Axis of weldhorizontal

Axis of weldhorizontal

Axis of weld vertical

VERTICAL Position Vu & Vd

OVERHEADPosition O

NOTE: One plate must be horizontal

NOTE: One plate must be horizontal

FLAT Position D

HORIZONTAL Position X

2665/02

Fig. 12.2.2(c) Plate fillet weld test positions

2.5.6 As an alternative to radiography, ultrasonic examin-ation may be carried out and acceptance criteria that are considered to result in equivalent weld quality (in accordancewith 2.5.5) are to be agreed, with the Surveyor, prior to thetests being carried out. Ultrasonic testing will be subject to thethickness limitation specified in Ch 13,2.12.5.

2.5.7 Where the test assembly does not satisfy the non-destructive examination acceptance criteria, the test is to berejected. A duplicate test assembly may be welded using theoriginal welding conditions. If this fails NDE, the welding procedure is to be considered as incapable of achieving therequirements without modification.

2.5.8 Subject to prior agreement with the Surveyor, whereunacceptable imperfections are of a volumetric nature and arelocalised in one small area of the test assembly, the test maybe permitted to continue and specimens for destructive testingmay be removed, avoiding this area.

2.6 Destructive tests – General requirements

2.6.1 The weld test assembly may only be sectioned fordestructive testing after any heat treatment and the requirednon-destructive examinations have been completed success-fully.

2.6.2 The dimensions of the test specimens and testingconditions are to be in accordance with the requirementsspecified in Chapter 2.

2.6.3 The results of destructive tests are to be assessedin accordance with the acceptance criteria specified in 2.12,unless other, more stringent requirements are specified for theapplication.

2.6.4 Where a weld test is made between materials of different grades, the acceptance criteria that are to be appliedare those applicable to the lower grade material.



LLOYD’S REGISTER6

Flat RotatedD Position

Horizontal (Fixed)X Position

Horizontal (Rotated)D Position

Overhead (Fixed)O Position

Multiple (Fixed)D + Vu + OorD + Vd + OPosition

2665/03

45°

45°

Fig. 12.2.2(d) Pipe fillet weld test positions

2.7 Destructive tests for steel butt welds

2.7.1 The test assembly is to be sectioned for mechanicaltesting in accordance with Figs. 12.2.3 or 12.2.4.

2.7.2 The longitudinal all weld metal tensile test specimen isto be of circular cross-section as detailed in Ch 11,2.1.1.Where more than one welding process or type of consumablehas been used to make the weld, test specimens are to beremoved from each respective area of the weld. This does notapply to the process or consumables used to make the rootor first weld run. During the test, the yield or proof stress, ultimate tensile strength, and elongation to failure are to berecorded.

2.7.3 Where approved welding consumables have beenused, the longitudinal all weld metal tensile test may be omitted. For Type C independent tanks intended for liquefiedgases, the all weld tensile test is mandatory for all welding procedure tests.


Chapter 12Section 2



2665/07

Test requirements

A One macro including hardness survey

B All weld metal tensile test

C Four bend tests.

Two root bends and two face bends for thickness up to 12 mm.

For thickness above 12 mm four side bends

D Two transverse tensiles

E Five sets of Charpy V-notch impact tests, notched at the following positions:

1 set at weld centre

1 set at fusion line (FL)

1 set at FL + 2 mm

1 set at FL + 5 mm (if required by Figs. 12.2.6 and 12.2.7)

1 set at FL + 10 mm (if required)

of weldCL

For retests if necessary

Approximately 300 mm

C

E

C

C

D

D

B

A

C

Fig. 12.2.3Butt welds in plate and pipe over 750 mm diameter

The diameter of the test piece is to be a minimum of D/2whereD is the maximum diameter of the pipe to be welded in construction

Test requirementsA Visual examinationB Surface crack detectionC 100% radiographic examinationD Two transverse tensile testsE Four bend tests. Four side bends for thickness greater than 12 mm. In other cases, two face and two root bendsF Four sets Charpy V-notch impact tests 1 set notched at centre of weld 1 set notched at fusion line (FL) 1 set notched at FL + 2 mm 1 set notched at FL + 5 mm (if required by Figs. 12.2.6 and 12.2.7)G One macro specimen including hardness survey

DE

E

F

500 mm approximately

GD

EE

Fig. 12.2.4Butt welds in pipe less than 750 mm diameter

2.7.4 The transverse tensile test specimen is to be of fullthickness with the dimensions shown in Ch 11,2.1.1. The tensile strength and fracture locations are to be reported.

2.7.5 Where the maximum load required to fracture thetransverse tensile specimen is likely to exceed the capacity ofthe tensile testing equipment, several tensile specimens maybe removed through the thickness and tested. Specimens areto be prepared such that they overlap in the thickness direction so that the full plate thickness is tested.

2.7.6 Transverse bend specimens of rectangular sectionare to be prepared with the weld centred in the middle of thespecimen as shown in Fig. 12.2.5. For material of thickness 12 mm or greater, the face and root bends may be substitutedby side bend tests. Where there is a significant differencebetween the strength of the weld and base material, longitudinal bend specimens may be used.The weld reinforce-ment may be removed by grinding or machining prior to testingand the edges rounded to a radius not exceeding 10 per centof the specimen thickness. Each specimen is to be bentthrough an angle of at least 180°. The bend test ratio is to bethe lesser of the following:(a) Df = (D/t) + 1or(b) Df = 100/Em (rounded up to the next whole number)where

Df = is the bend test ratio(D/t) = is the value from Tables 11.3.3, 11.4.3 or 11.8.2

in Chapter 11, as appropriateEm = is the minimum specified percentage elongation

for the test material (based on a proportionalgauge length of 5,65 )

2.7.7 Where the weld test is made between differentmaterial types, the requirements of 2.7.8 are to be applied tothe material with the lower toughness specification.

So

2.7.8 For hull structural steels, impact test specimens areto be prepared from the locations shown in Figs. 12.2.6 or12.2.7, with the notch perpendicular to the plate surface andhave the dimensions and proportions in accordance with Ch 2,3. Where more than one welding process or type of consumable has been used to make the weld, test specimensare also to be removed from these respective parts of the weld.Note that this does not apply to the welding process or consumables used solely to make the root or first weld run.Where the weld thickness exceeds 50 mm, an additional set ofimpact tests is required from the root area of the weld irrespective or whether different welding process or weldingconsumables are used as shown in Figs. 12.2.6 and 12.2.7.

2.7.9 For offshore structures and pressure vessels,impact test specimens are not required to be notched at theFL + 10 mm location. Where more than one welding processor type of consumable has been used to make the weld, testspecimens are to be removed from the respective areas of theweld. This does not apply to the process or consumablesused solely to make the root or first weld run.

2.7.10 For pressure vessels and tanks employed in trans-portation of liquefied gases, Charpy impact test locations fromthe weld and heat affected zone are to be in accordance withFig. 12.2.8.

2.7.11 At least one macro examination specimen is to beremoved from the test plate, near the end where welding started.The specimen is to include the complete cross-section of theweld and the heat affected zone and be prepared and etchedto clearly reveal the weld runs and the heat affected zone.Examination is to be performed under a magnification ofbetween x5 and x10.

2.7.12 A chemical analysis of the weld metal is to be performed on the macro specimen where approved welding consumables have not been used. The results are to complywith the limits given in the welding consumable specification.

2.7.13 A Vickers hardness survey is to be performed onthe macro specimen taken from the weld start end of the testassembly in accordance with that shown in Fig. 12.2.9, usinga test load not in excess of 10 kg. For each row of indents,there are to be a minimum of 3 individual indentations in theweld metal, the heat affected zones (both sides) and the basemetal (both sides). The recommended distance betweenindents is 1,0 mm, but the distance between indents shouldnot be less than the minimum specified in ISO 6507/1.

2.8 Destructive tests for steel fillet welds

2.8.1 Fillet weld test assemblies are to be sectioned fordestructive testing in accordance with Fig. 12.2.1(c) and asfollows:(a) two fracture tests;(b) three macro-sections;(c) one hardness survey.

2.8.2 Two fracture test specimens are to be removedfrom the test weld and are to be subjected to testing by bendingthe upright plate onto the through plate to produce fracture,as shown in Fig. 12.2.1(c).



LLOYD’S REGISTER8

(a) root or face bend specimen t ≤ 12 mm

t

1,5tWeld

(b) side bend specimen t = material thickness

t

10 mm

Fig. 12.2.5 Transverse bend test specimens

2.8.3 At least three macro examination specimens are tobe removed from the test plate. The specimens are to includethe complete cross-section of the weld and the heat affectedzone and is to be prepared to clearly reveal the weld runs andthe heat affected zone. One of the specimens is to include aweld stop/start position. Examination is to be performed undera magnification of between x5 and x10.

2.8.4 A Vickers hardness survey is to be performed onthe macro specimen taken from the weld start end of the testassembly in accordance with that shown in Fig. 12.2.10, usinga test load not exceeding 10 kg.

2.9 Destructive tests for T, K, Y steel nozzlewelds

2.9.1 Full penetration ‘T’, ‘K’ and ‘Y’ joints for structuralapplications and nozzle welds for pressure vessels are to besectioned for testing in accordance with Fig. 12.2.11 andtested as detailed below:(a) three macro specimens;(b) impact tests from the weld, fusion line and fusion line + 2

(where the material thickness permits);(c) one hardness survey.

In addition, butt weld tests are to be performed in accordancewith 2.7, using the same welding conditions, in order to verifyacceptable weld and heat affected zone properties.

2.9.2 The impact tests are to be removed from the vertical(up) position ‘B’ in Fig. 12.2.11 and tested in accordance with2.7.8.

2.9.3 A Vickers hardness survey is to be performed onthe macro-section removed from position ‘A’ or ‘C’ in accor-dance with that shown in Fig. 12.2.12 using a test load notexceeding 10 kg.

2.10 Destructive tests for steel pipe branch welds

2.10.1 Pipe branch welds may be by either full penet-ration, partial penetration or fillet welded, depending on theapplication and the approved plans. Where these types ofwelded joints are used, tests are to be performed which simulate the construction conditions.


Chapter 12Section 2



a b c1-2 mm

a b c1-2 mm 2nd side

1st side


1st side

a

a b c1-2 mm

a b

(a) t ≤ 50 mm, see Note

(a) t > 50 mm

NOTE

For one side single run welding over 20 mm notch location ‘a’ is to be added on root side

Notch locations:a : centre of weld ‘WM’b : on fusion line ‘FL’c : in HAZ, 2mm from fusion line

Fig. 12.2.6 Locations of V-notch for butt weld of normal heat input (heat input ≤ 50 kJ/cm)

2.10.2 The test weld assembly is to simulate the smallestangle between the branch and main pipe and is to besubjected to macro-examination and hardness testing, asfollows:(a) For a branch weld that is full penetration, testing is to be

performed in accordance with the requirements for ‘T’,‘K’ and ‘Y’ joints in 2.9.

(b) For a branch weld that is either a partial penetration orfillet weld, testing is to be in accordance with the require-ments for fillet welds in 2.8.

2.11 Destructive tests for weld cladding of steel

2.11.1 Where weld cladding or overlay is allowed byChapter 13, and is considered as providing strength to thecomponent to which it is welded, the type and location of testspecimens are to be in accordance with Fig. 12.2.13, exceptthat micro-sections are not required. Impact tests may beomitted where the base material does not have specifiedimpact properties. The longitudinal tensile and bend tests areto be tested in a similar manner to transverse specimensspecified in 2.7.2 and 2.7.6, respectively.

2.11.2 Where the weld cladding is not considered as contributing to the strength of the component, but is requiredfor corrosion or wear resistance, the type and location of testspecimens are to be in accordance with Fig. 12.2.13, exceptthat tensile and impact tests are not required.

2.11.3 Where the weld cladding is applied for corrosionresistance, in addition to the above, weld metal analysis is tobe performed on one of the micro-sections, on the final weldsurface but 2 mm deep. The analysis is to be within the limitsspecified for the corrosion resistance required.

2.12 Mechanical test acceptance criteria for steels

2.12.1 Longitudinal all weld metal tensile test:(a) In general, the longitudinal all weld tensile test is to meet

the minimum properties specified in Tables 11.3.2 or11.4.2 in Chapter 11, as appropriate to the grade of steeland welding process used in the test.

(b) Where the application is such that no consumableapprovals are specified in Chapter 11, the longitudinal allweld tensile test tensile is to meet the minimum propertiesspecified for the base materials used in the test.




a b c1-2 mm


1st side


1st side

a

a b c1-2 mm

a b


(a) t > 50 mm

NOTE

For one side welding with thickness over 20 mm notch location ‘a’, ‘b’ and ‘c’ are to be added on root side

Notch locations:a : centre of weld ‘WM’b : on fusion line ‘FL’c : in HAZ, 2 mm from fusion lined : in HAZ, 5 mm from fusion linee : in HAZ, 10 mm from fusion line in case of heat input > 200 kJ/cm

d e d e

d e

c

d e

c

Fig. 12.2.7 Locations of V-notch for butt weld of high heat input (heat input > 50 kJ/cm)

(c) For pressure vessels manufactured from carbon orcarbon/manganese steels, the tensile strength from thelongitudinal all weld tensile test is not to be less than theminimum specified for the plate material and is not to be more than 145 N/mm2 above this value, seeCh 13,4.8.3.

(d) For tanks intended for liquefied gases, the weld metalstrength may be lower than the minimum specified forthe base metal provided that the application has designapproval. In such cases the strength is not to be lessthan that specified in the approved design.

2.12.2 Transverse tensile test: The tensile strengthmeasured from the transverse tensile test is not to be lessthan the minimum specified for the base material used in thetest. For tanks intended for liquefied gases, a lower ultimatetensile may be accepted subject to design approval as in2.12.1(d).

2.12.3 Bend tests:(a) In general, bend tests are to exhibit no defects exceeding

3,0 mm measured in any direction across the tensionface of the specimen after being bent over the requireddiameter of former to the appropriate angle.

(b) Bend tests for pressure vessel applications are to exhibitno defects exceeding 3,0 mm measured along the specimen or 1,5 mm measured transverse to the specimen axis, after bending.

(c) In all cases, premature failure of the bend tests at theedges of the specimen is to not be cause for rejectionunless these are associated with a weld defect.

2.12.4 Impact toughness tests:(a) Impact test specimens for hull construction are to be

tested at the temperature, and are to achieve the mini-mum impact energy, as specified in Tables 12.2.2 and12.2.3.

(b) Impact test specimens for applications other than hullconstruction are to be tested at the same temperatureand achieve the same minimum energy values, as specified for the base materials used in the test.


Chapter 12Section 2



a b c1-2 mm


1st side


1st side

a

a b c1-2 mm

a b


(a) t > 50 mm

NOTE

For one side welding with thickness over 20 mm notch locations ‘a’, ‘b’ and ‘c’ are to be added on root side

Notch locations:a : centre of weld ‘WM’b : on fusion line ‘FL’c : in HAZ 1 mm from fusion lined : in HAZ 3 mm from fusion linee : in HAZ 5 mm from fusion linef : in base metal remote from weld (Type C independent tanks only)

d e d e

d e

c

d e

c

Fig. 12.2.8 Locations of V-notch tests for butt welds intended for liquefied gas containment systems

(c) Impact test acceptance criteria are to be in accordancewith the above unless the Rules applicable to the particular construction specify more stringent require-ments.

(d) For quench and tempered steels, the required testtemperature and absorbed energy are to be in accordance with that specified for the parent materials.

2.12.5 Macro-examination: The macro-section is toreveal an even weld profile blending smoothly with the basematerial. The weld dimensions are to be in accordance withthe requirements of the pWPS and any defects present are tobe assessed against the non-destructive examination accep-tance criteria given in 2.5.5.

2.12.6 Hardness surveys: The maximum hardness valuereported, is not to exceed 350 Hv for steels with a specifiedminimum yield strength up to ≤420 N/mm2, nor exceed 420 Hv for steels with a specified minimum yield strength in therange 420 N/mm2 to 690 N/mm2.

2.12.7 Weld fracture or break tests (for pressure vesseltest welds): The faces of the broken fillet weld fracture orweld break test are to be examined for defects and assessedin accordance with the non-destructive acceptance criteriagiven in ISO 5817 Level B, except for excess convexity andexcess throat thickness where Level C will apply.




h ≤ 2 mm ≤ 0,5 mm

S S S

4607/13

Parent metalWeld metalGCHAZ

HAZ

2 mm max.

2 mm max.

2 mm max.

2 mm max.

2 mm max.

2 mm max.4607/30

HAZ Heat affected zoneGCHAZ Grain coarsened heat affected zoneS Indentation spacing

Fig. 12.2.9 Hardness testing locations for butt welds


Chapter 12Section 2



4607/23a

2 mm max.

2 m

m m

ax.

h ≤ 2 mm

h ≤ 0,5 mm

h ≤

2 m

m

h ≤ 0,5 mm

h ≤

2 m

m

S

S

S

S

S

h ≤

2 m

m

4607/36

GCHAZ HAZ


Fig. 12.2.10 Hardness test locations for fillet welds

2.13 Failure to meet requirements (Retests)

2.13.1 Where a tensile, bend or hardness specimen fails tomeet requirements, further test specimens may be removedand tested in accordance with the requirements of Ch 2,1.4.1.

2.13.2 Where an impact specimen fails to meet require-ments, a further set of three specimens may be removed andtested in accordance with the requirements of Ch 2,1.4.4.

2.13.3 Where a macro specimen reveals a defect that isplanar in nature, the welding procedure test is to be consideredas not satisfying the requirements and a new test assembly isrequired.

2.13.4 Where a macro specimen does not meet require-ments as a result of a volumetric imperfection exceeding thepermitted size, two additional specimens may be removedfrom the same test weld and examined. If either of thesemacro-sections also fails to satisfy the requirements, the welding procedure is to be considered as not having met therequirements.




h ≤ 0,5h ≤

2 m

m

h ≤ 2 mm

h ≤ 2 mm

h ≤ 2 m

m

h ≤

0,5

mm

h ≤

0,5

mm

h ≤ 0,5 mm

S

SS

S

S

S

4607/24

GCHAZHAZ


Fig. 12.2.12 Hardness test locations for T, K and Y joints

Edge preparation and fit-upto be as detailed in weldingprocedure

2665/04Assembly to be welded

with main axis in thevertical position

Position ‘A’

Position ‘B’

Position ‘C’

Fig. 12.2.11Location of macro-examination test specimens for

T, K and Y joints

2.13.5 If there is a single hardness value above the maximumvalues specified, additional hardness tests are to be carried out, either on the reverse of the specimen, or after sufficient grinding of the tested surface. None of the additionalhardness values is to exceed the maximum hardness valuesspecified, otherwise the welding procedure is to be consid-ered as not having met the requirements.

2.13.6 Where there is insufficient material available in thewelded test assembly to provide re-test specimens, subject toprior agreement with the Surveyor, a second assembly may bewelded using the same conditions as the original test weld.


Chapter 12Section 2



5 & 6

1 & 2

1 & 2

3

5 & 6

2

4

2

100 mm minimum5-long. macro andhardness survey

3-weld impact

Test

dia

met

er

1 and 2 long. bend and tensile 6-Trans. micro

4-HAZ impacts6-Trans.micro

Weld cladding5-long. macro andhardness survey

Test specimens1 Longitudinal tensile test to include the weld metal, heat affected zone (HAZ) and base metal.2 Longitudinal side bend test to include the weld metal, heat affected zone (HAZ) and base metal.3 Weld metal Charpy V notch impact test.4 HAZ Charpy impact test from Fusion Line and Fusion Line + 2 mm.5 Longitudinal macro-section and hardness survey.6 Transverse micro-section.NOTE

In the case of shafts and pipes of circular section, the longitudinal direction is parallel to the centreline of the shaft or pipe axis.

Fig. 12.2.13 Type and location of test specimens for weld cladding

Grade of steelTest temperature

(°C)see Note 4

Value of minimum energy absorbed (J), see Note 4

Manual or semi-automatic welded joints

Downhand, Horizontal,Overhead

Vertical upward,Vertical downward

A, see Note 3B, see Note 3, D

EA32, A36D32, D36E32, E36F32, F36

A40D40E40F40

200

–20200

–20–40

200

–20–40

34

39

34

39

Automatically welded joints

NOTES1. Steel with yield strength greater than 390 N/mm2 is not permitted in thickness less than 50 mm, see Table 3.3.1 in Chapter 3.2. These requirements are to apply to test piece of which butt weld is perpendicular to the rolling direction of the plates.3. For grade A and B steels average absorbed energy on fusion line and in heat affected zone is to be a minimum of 27 J.4. For Naval ships both the test temperature and value of minimum energy absorbed are to be those specified for the parent material.

Table 12.2.2 Impact test requirements for butt joints (t ≤ 50 mm) see Notes 1 and 2

47

2.14 Test records

2.14.1 The procedure qualification record (PQR) is to beprepared by the manufacturer and is to include details of thewelding conditions used in the test specified in 2.2 and theresults of all the non-destructive examinations and destructivetests, including re-tests.

2.14.2 Provided that the PQR lists all the relevant variablesand there are no inconsistent features and the results satisfythe requirements, the PQR may be endorsed by the Surveyoras satisfying the requirement of the Rules, see also 1.1.4.

2.15 Range of approval

2.15.1 A welding procedure qualification test that has successfully met the requirements may be used for a widerrange of applications than those used during the test.

2.15.2 Changes outside of the ranges specified are torequire a new welding procedure test.

2.15.3 Other ranges of approval from those specified inthis Section may be agreed with the Surveyor, provided thatthey are in accordance with recognised National orInternational Standards.

2.15.4 Manufacturer. A welding procedure qualified by amanufacturer is valid for welding in workshops under the sametechnical and quality management.

2.15.5 Welding process and technique. The weldingprocess and welding techniques approved are to be thoseemployed during the welding procedure qualification test.Where multiple welding processes are used, these are to beemployed in the same order as that used in the welding procedure qualification test. However, it may be acceptable todelete or add a welding process where it has been used solely to make the first weld run in the root of the joint, providedback gouging or grinding of the root weld is specified on theWPS. For multi-process procedures, the welding procedureapproval may be carried out with separate welding procedure tests for each welding process.

2.15.6 Welding positions. Approval for a test made in anyposition is restricted to that position. To qualify a range of positions, test assemblies are to be welded for the highestheat input position, and the lowest heat input position, and allapplicable tests are to be made on those assemblies. Theabove excludes welding in the vertical position with travel inthe downward direction which will always require separatequalification testing and only be acceptable for that position.

2.15.7 Joint types. A qualification test performed on a buttweld may be considered acceptable for fillet and partial penetration welds, provided the same welding conditions areused. The range of approval depending on the type of joint forbutt welds is given in Table 12.2.4.




Value of absorbed energy (J, min), see Note 2Test temperature

(ºC) Manual or semi-automatic welded jointsSee Note 2 Automatically

Downhand, Horizontal, Vertical upward, welded jointsOverhead Vertical downward

A 20 34 34 34B 0 34 34 34D 0 47 38 38E –20 47 38 38

AH32, AH36 20 47 41 41DH32, DH36 0 47 41 41EH32, EH36 –20 47 41 41FH32, FH36 –40 47 41 41

AH40 20 50 46 46DH40 0 50 46 46EH40 –20 50 46 46FH40 –40 50 46 46

EH47 –20 64 64 64

NOTES1. These requirements are to apply to test piece of which butt weld is perpendicular to the rolling direction of the plates.2. For the Naval ships both the test temperature and value of minimum absorbed energy are to be those specified for the parent material.

Table 12.2.3 Impact test requirements for butt joints (t > 50 mm) see Note 1

Grade of steel

2.15.8 Range of material types:(a) A qualification test performed on one strength level of

steel may be used to weld all similar materials with thesame or lower specified minimum yield stress with theexception of the two-run (T) or high welding heat input(A) techniques where acceptance is limited to thestrength level used in the test. Similarly, a qualificationtest performed on a steel with one toughness level may be considered acceptable for welding all similar materials with the same or three toughness grades lowerspecified minimum toughness level.

(b) A qualification test performed on H47 strength gradesteels may be used to weld the steel of the samestrength level or grade H40 and all lower toughnessgrades to that tested.

(c) For high strength quenched and tempered steels, foreach strength level, welding procedures are consideredapplicable to the same and lower toughness grades asthat tested. For each toughness grade, welding procedures are considered applicable to the same andone lower strength level as that tested. The approval ofquenched and tempered steels does not qualify thermo-mechanically rolled steels (TMCP steels) and viceversa.

(d) For weldable C and C-Mn steel forgings, welding proce-dures are applicable to the same and lower strength levelas that tested. The approval of quenched and temperedsteel forgings does not qualify other delivery conditionsand vice versa.

(e) For weldable C and C-Mn steel castings, welding procedures are applicable to the same and lowerstrength level as that tested. The approval of quenchedand tempered steel castings does not qualify other delivery conditions and vice versa.Dissimilar materials. Where a qualification test has beenperformed using dissimilar materials, acceptance is tobe limited to the materials used in the test.

2.15.9 Thickness and diameter range:(a) For straight butt welds, the material thickness range to

be approved is to be based on the thickness of the testpiece and the type of weld as shown in Table 12.2.5.

(b) For butt welds between plates of unequal thickness, thelesser thickness is the ruling dimension.

(c) For fillet welds and ‘T’ butt welds, Table 12.2.5 is to beapplicable to both the abutting and through memberthicknesses. In addition to the requirements of Table 12.2.5, the range of approval of throat thickness‘a’ for fillet welds is to be as follows:• single run: 0,75a to 1,5a• multi-run: as for butt welds with multi-run (i.e. a = t)

(d) Notwithstanding any of the above, the approval of maximum thickness of base metal for any technique isto be restricted to the thickness of the test assembly ifthree of the hardness values in the heat affected zoneare found to be within 25 Hv of the maximum permitted.

(e) The material diameter range to be approved is to bebased on the diameter of the test piece and type of weldas shown in Table 12.2.6.


Chapter 12Section 2



Type of welded joint for test assemblyRange of approval

Butt welding One side With backing A A,CWithout backing B A,B,C,D

Both sides With gouging C CWithout gouging D C,D

Table 12.2.4 Range of approval for different typesof butt joints

Range approvedTest thickness,

see Note 1 All multi-run butt All single-run or two-run(t in mm) welds and all fillet welds two-run (T technique)

see Notes 3 and 4 butt welds

t ≤ 3 t to 2t 0,7t to 1,1t

3 < t ≤ 12 3 to 2t 0,7t to 1,1t

12 < t ≤ 100 0,5t to 2t, 0,7t to 1,1tsee Note 2 see Note 5

t > 100 0,5t to 1,5t 0,7t to 1,1tsee Note 5

NOTES1. Where the test plates have dissimilar thickness, the thick-

ness, t, is to be based on the minimum thickness for buttwelds and the maximum thickness for fillet welds.

2. Subject to a maximum limit of 150 mm.3. For multi process procedures, the recorded thickness contri-

bution of each process is to be used as a basis for the rangeof approval of the individual welding process.

4. For vertical down welding, the test piece thickness, t, is theupper limit of the range of application.

5. For processes with heat input over 5,0 kJ/mm, the upperlimit of the range of approval is to be 1,0 t.

Table 12.2.5 Welding procedure thickness approvalrange – Butt welds

Table 12.2.6 Diameter range approved

Diameter used for test, Range of diameters see Note 1 approved

D ≤ 25 mm 0,5D to 2D

D > 25 mm > 0,5D, see Note 2

NOTES1. D is the outside diameter of the pipe or the smallest side

dimension of rectangular hollow section.2. Lower diameter range limited to 25 mm minimum.

2.15.10 Welding consumables:(a) For manual and semi-automatic welding used for the fill

and capping weld runs, it may be acceptable to changethe brand or trade name of the welding electrode or wirefrom that used in the test, provided the proposed alternative has the same or higher approval grading andthe same flux type (e.g. basic low hydrogen, rutile, etc.)as used in that test.

(b) For the consumable used to make the root weld of fullpenetration butt welds made from one side only, nochange in the type or trade name of the consumable orbacking material is permitted. Alternative backing materials may be used provided they are equivalent tothose used for approval. Where the approved backingmaterial is a low hydrogen grade and the steel beingwelded requires a low hydrogen backing material, testingof the alternative backing material is to confirm compli-ance with the requirements of Ch 11,7

(c) For processes with heat input over 5 kJ/mm, no changein the type or trade name of the consumable is permitted.

2.15.11 Shielding gas. For gas shielded welding processes,a change in shielding gas composition from that used in thetest will require a new qualification test.

2.15.12 Heat Input. The upper limit of heat input approvedis 25 per cent greater than that used in the test, or 5,5 kJ/mm,whichever is the smaller. With heat input over 5,0 KJ/mm, theupper limit is 10 per cent above that used in the test. In allcases, the lower limit of heat input approved is 25 per centlower than that used in the test.

2.15.13 Current type. The current type used during thequalification test is to be the only type approved. Additionally,changes from or to pulsed current require new qualificationtests.

2.15.14 Preheat temperature. The temperature used duringthe test is to be the minimum approved. Higher temperaturesmay be specified for production welds up to the maximuminterpass temperature. Where hardness tests have been performed that exhibit results near the maximum permitted, anincrease in preheat temperature is required when weldingmaterial of greater thickness than that used in the test.

2.15.15 Interpass temperature. The maximum interpasstemperature recorded during qualification testing is to be themaximum approved. Lower temperatures may be specified forproduction welding, but no lower than the minimum preheattemperature.

2.15.16 Post-weld heat treatment. A qualification test performed with no post weld heat treatment is only acceptablefor production welding where no heat treatment is applied.Where the qualification test has included a post weld heattreatment, this is to be applied to all welds made with thewelding procedure. The average specified soak temperaturemay vary by up to 25°C from that tested.

2.15.17 Shop primers. Welding procedure qualification withshop primers qualifies welds without primer, but not viceversa.

2.16 Welding procedure specification (WPS)

2.16.1 A welding procedure specification (WPS) is to beprepared by the manufacturer detailing the welding conditionsand techniques to be employed for production welding. TheWPS is to be based on the conditions and variables used during the qualification test, and is to include all the ranges ofthe essential variables specified in 2.2.1 and 2.15.

2.16.2 The WPS should reference the procedure qualifica-tion record upon which it is based and is to be approved bythe Surveyor prior to commencing production welding.

■ Section 3Specific requirements for stainless steels

3.1 Scope

3.1.1 The requirements of this Section relate to the groupof steel materials classed as stainless steels and includeaustenitic and duplex grades and martensitic grades.

3.1.2 In all cases, welding procedure tests are to be performed generally in accordance with Section 2 with the specific requirements specified below.

3.2 Austenitic stainless steels

3.2.1 The requirements of this Section relate to the group ofstainless steel materials that are austenitic at ambient and sub-zero temperatures, (e.g., 304L, 316L types), see Table 3.7.1 inChapter 3.

3.2.2 Impact tests are to be performed from specimensremoved from the weld metal. Tests in the heat affected zoneare not required.

3.2.3 Hardness tests are generally not required.

3.2.4 For cryogenic or corrosion resistant applications,the ferrite content in the weld cap region is to be measuredand is to be in the range 2 to 10 per cent, with the exceptionof grades S 31245 and N 08904 where the content is to benominally zero.

3.2.5 A qualification test performed on an austeniticgrade may be considered acceptable for welding otheraustenitic steels with the same or lower level of alloying elements and the same or lower tensile strength.

3.2.6 A qualification test performed for cryogenic applica-tions may be considered acceptable for chemical applications,but not vice versa.


Welding Qualifications Chapter 12Sections 2 & 3


3.3 Duplex stainless steels

3.3.1 The requirements of this Section relate to the groupof stainless steel materials that have a ferritic-austenitic structure and are usually referred to as duplex or super duplexstainless steels (e.g.,S 31803, S 32760).

3.3.2 Impact test specimens are to be removed from theweld and heat affected zone in accordance with Section 2 withthe exception that impact test specimens notched at the FL + 10 mm location are not required. The specimens are tobe tested at a temperature of –20°C or the minimum design temperature whichever is the lower and exhibit a minimumaverage energy of 40 J.

3.3.3 The corrosion resistance is to be maintained in thewelded condition and the following tests are to be performedto demonstrate acceptable resistance, unless agreed other-wise.(a) A sample is to be removed from the weld and heat

affected zone for micro-structural examination and is tobe suitably prepared and etched so that the micro-structures of the weld and heat affected zones can beexamined at a magnification of x200 or higher. Themicro-structure of the weld and heat affected zone is tobe examined, the percentage grain boundary carbidesand intermetallic precipitates is to be reported.

(b) The ferrite content in the un-reheated weld cap and capHAZ along with the weld root and root HAZ are to bemeasured and reported. The ferrite content is to be inaccordance with Table 12.3.1. Where the intendedconstruction is such that the corrosion medium is only incontact with one surface of the weld (i.e., the weld root),the ferrite determination need only be reported in thatsurface area.

(c) Corrosion testing is to be performed on samplesremoved from the weld such that both the weld and HAZare included in the test. The critical pitting temperature isto be determined in accordance with ASTM G48 MethodC and meet the requirements specified in Table 12.3.1.The cap and root surfaces are to be inspected forevidence of pitting and may require probing the surfacewith a needle. Pitting found on the ends of the specimenin the weld cross-section may be ignored. The use of theweight loss method for corrosion testing may beaccepted subject to special consideration.





Duplex Stainless Weld and HAZ Minimum Critical Steel Ferrite content Pitting Temperature

Material Grade (CPT)

S 31260 30 to 70% 20°CS 31803 30 to 70% 20°CS 32550 35 to 65% 25°CS 32750 35 to 65% 25°CS 32760 35 to 65% 25°C

Table 12.3.1 Requirements for ferrite content andcorrosion tests for duplex stainlesssteel test welds

3.3.4 Where the test weld is between a grade of carbonsteel and duplex stainless steel, the test requirements of3.3.3(a) and (c) are not required and the ferrite content of theweld and the duplex heat affected zone are to be reported forinformation.

3.3.5 A qualification test performed on a duplex stainlesssteel grade may be considered acceptable for welding otherduplex grades which have the same or less stringent mechanicalor corrosion properties.

3.3.6 The range of heat input is not to vary by more than+10 per cent or –25 per cent from that used during testing.

3.4 Martensitic stainless steels

3.4.1 The requirements of this Section relate to the groupof stainless steel materials that have a martensitic structure atambient temperatures, see Table 4.5.1 in Chapter 4.

3.4.2 The results of the hardness survey results are to bereported for information purposes only.

3.4.3 A qualification test is considered acceptable only forthe grade of material used in the test.

■ Section 4Welding procedure tests for non-ferrous alloys

4.1 Requirements for aluminium alloys

4.1.1 The requirements for welding procedure qualifica-tion tests for aluminium alloys are to be in accordance with thegeneral requirements of Section 2 with the following excep-tions and specific requirements.

4.1.2 Non-destructive examination is to be performed inaccordance with 2.5 and the assessment of results is to be inaccordance with Table 12.4.1 and Table 12.4.2.

4.1.3 Acceptance of the mechanical tests is to be inaccordance with Ch 11,9. Welding of the strain hardened andheat treatable aluminium alloys will generally result in a loss oftensile strength in the heat affected zone below that specifiedfor the base materials and the tensile strength acceptance criteria to be applied is that specified for the material in theannealed or ‘as fabricated’ condition. Minimum values of tensile strength measured on the transverse tensile samplesare given in Table 12.4.3.

4.1.4 Impact tests and hardness surveys are not requiredfor aluminium alloys.

(c) The qualification of a procedure carried out on a testassembly of thickness t is valid for the thickness rangegiven in Table 12.4.6. In the case of butt joints betweendissimilar thicknesses, t is the thickness of the thinnermaterial. In the case of fillet joints between dissimilarthicknesses, t is the thickness of the thicker material. Inaddition to the requirements of Table 12.4.6, the range ofthe qualification of throat thickness of fillet welds, a, isgiven in Table 12.4.7. Where a fillet weld is qualified by a butt weld test, the throat thickness range qualified is tobe based on the thickness of the deposited weld metal.

(d) The range of shielding gas compositions approved is tobe in accordance with Table 11.9.2 in Chapter 11.

(e) A change in the brand or trade name of the filler metalfrom that used in the test is acceptable, provided thatthe proposed consumable has the same or higherstrength grading.

(f) A change in post-weld heat treatment or ageing is notpermitted, except that for the heat treatable alloys, artificialageing may give approval for prolonged natural ageing.




4.1.5 Four side bend tests may be used in place of rootand face bends where the test thickness exceeds 12 mm, andlongitudinal bend tests may be used instead of transverse testswhere the test weld is between different grades of alloy. Bendspecimens are to be bent round a former in accordance withTable 11.9.1 in Chapter 11, with the exception that the 6000 series alloys may be bent round a former with D/t = 7.

4.1.6 The ranges of approval to be applied to the WPSare to be as specified for steel in 2.15 with the followingexceptions:(a) The welding positions approved are as detailed in

Table 12.4.4.(b) The aluminium alloys are grouped into three groups as

follows:• Group A: aluminium-magnesium alloys, with Mg

content ≤3,5 per cent (alloy 5754).• Group B: aluminium-magnesium alloys with 4 per

cent ≤ Mg ≤ 5,6 per cent (alloys 5059, 5083,5086, 5383 and 5456).

• Group C: aluminium-magnesium-silicon alloys(alloys 6005A, 6061 and 6082). For each group,the qualification made on one alloy qualifies the procedure also for the other alloys inthe group, with equal or lower tensile strengthafter welding. The qualification made on group Balloys qualifies the procedure for Group A alloysalso. Approval for the range of material grades issummarised in Table 12.4.5.

Surface discontinuityClassification according to

Acceptance criteriaISO 6520-1

Crack 100 Not permitted

Lack of fusion 401 Not permitted

Incomplete root penetration in butt joints welded 4021 Not permittedfrom one side

Surface pore 2017 d ≤ 0,1s or 0,1amax. 1,0 mm

Uniformly distributed porosity (see Note 1) 2012 ≤ 0,5% of area

Clustered porosity 2013 Not permitted

Continuous undercut 5011 Not permitted

Intermittent undercut 5012 h ≤ 0,1t or 0,5 mm (whichever is the lesser)

Excess weld metal (see Note 2) 502 h ≤ 1,5 mm + 0,1b or 6 mm (whichever is the lesser)

Excess penetration 504 h ≤ 4 mm

Root concavity (see Note 2) 515 h ≤ 0,05t or 0,5 mm (whichever is the lesser)

Linear misalignment (see Notes 3 and 4) 507 h ≤ 0,2t or 2,0 mm (whichever is the lesser)

Symbols

a = nominal throat thickness of a fillet weldb = width of weld reinforcementd = diameter of a gas poreh = height or width of an imperfections = nominal butt weld thicknesst = wall or plate thickness (nominal size)

NOTES1. To be in accordance with EN ISO 10042.2. A smooth transition is required.3. The limits for linear misalignment relate to deviations from the correct position. Unless otherwise specified, the correct position is to be

taken when the centrelines coincide.4. Dimensional tolerances not specified in these Rules are to be mutually agreed between the manufacturer and the Surveyor.

Table 12.4.1 Acceptance criteria for surface imperfections of aluminium alloys


Welding QualificationsRULES FOR THE MANUFACTURE, TESTING AND CERTIFICATION OF MATERIALS, July 2014

Chapter 12Section 4

Internal discontinuityClassification according to

Acceptance criteriaISO 6520-1



Incomplete penetration 402 Not permitted

Single gas pore 2011 d ≤ 0,2s or 0,2a or 4 mm (whichever is the lesser)

Linear porosity (see Note 2) 2014 Not permitted

Uniformly distributed porosity (see Note 2) 2012 0,5t to 3t ≤ 1% of area> 3t to 12t ≤ 2% of area> 12t to 30t ≤ 3% of area> 30t ≤ 4% of area

Clustered porosity (see Note 1) 2013 dA ≤ 15 mm or wp (whichever is the lesser)

Elongated cavity 2015 l ≤ 0,2s or 0,2a or 3 mm (whichever is the lesser)Wormhole 2016

Oxide inclusion (see Note 2) 303 l ≤ 0,2s or 0,2a or 3 mm (whichever is the lesser)

Tungsten inclusion 3041 l ≤ 0,2s or 0,2a or 3 mm (whichever is the lesser)

Copper inclusion 3042 Not permitted

Multiple imperfections in any cross-section — The sum of the acceptable individual imperfections in any cross-section is not to exceed 0,2t or 0,2a(whichever is the lesser)

Symbols

a = nominal throat thickness of a fillet weldd = diameter of a gas poreh = height or width of an imperfections = nominal butt weld thicknesst = wall or plate thickness (nominal size), in mm

wp = width of weld or width or height of cross-sectional areadA = diameter of area surrounding gas pores

l = length of imperfection in longitudinal direction of weld

NOTES1. For this acceptance criterion, linear porosity is to be considered as three aligned gas pores in a length of 25 mm.2. Porosity is to be determined in accordance with ISO 10042. The requirements for a single gas pore are to be met by all the gas pores

within this circle. Systematic clustered porosity is not permitted.

Table 12.4.2 Acceptance criteria for internal imperfections of aluminium alloys

Parent material Grade Minimum tensile strength(alloy designation) (N/mm2)

5754 1905086 2405083 2755383 2905059 3305456 290

6005A 1706061 1706082 170

Table 12.4.3 Tensile strength requirements bygrade for aluminium alloys

Test position Positions approved

Downhand D DHorizontal-vertical X D, XVertical up Vu D, X, VuOverhead O D, X, Vu and O

NOTEWelding in vertical down (Vd) position is not recommended.

Table 12.4.4 Welding procedure approval, weldingpositions for aluminium alloys

4.2 Requirements for copper alloys

4.2.1 The requirements for welding procedure qualificationtests for copper alloys are to be in accordance with the require-ments for steel as given in Section 2 with the following exceptions and additions.

4.2.2 Impact tests on copper alloys are not required.

4.2.3 Hardness tests are not required for seawater service.

4.2.4 For the welding of cast copper alloys for propellers,the minimum tensile strength from the transverse tensile test isto be in accordance with Table 12.4.8.

4.2.5 Bend tests are to be performed over a diameter offormer as detailed in Table 12.4.9.

4.2.6 The range of approval to be applied to the WPS isto be as specified in 2.15 with the exception of the materialgrades which are detailed in Table 12.4.10.




Thickness of test assembly, Range of qualification Range of qualificationt (mm) Multi pass welds All single-run or two-run (T technique) butt welds

t ≤ 3 0,5 to 2t 0,5t to 1,1t

3 < t ≤ 20 3 to 2t 0,5t to 1,1t

t >20 ≥ 0,8t 0,5t to 1,1t

Table 12.4.6 Range of qualification for parent material thickness

Material used in qualification test

Material Grades approved

5754 5754

5086 5086 5754

5083 5083 5086 5754

5383 5383 5083 5086 5754

5059 5059 5383 5083 5086 5754

5456 5456 5383 5083 5086 5754

6005A 6005A 6082 6061

6082 6005A 6082 6061

6061 6005A 6082 6061

NOTEApproval includes all the different strained and tempered conditions in each case.

Table 12.4.5 Welding procedure approval, aluminium material grades approved

Minimum tensile strengthAlloy designation(N/mm2)

CU 1 370

CU 2 410

CU 3 500

CU 4 550

Table 12.4.8 Minimum transverse tensile strengthsfor welded copper alloy propellers

Throat thickness of test piece,a (mm) Range of qualification

a < 10 0,75 a to 1,5 a

a ≥ 10 ≥ 7,5

Table 12.4.7 Range of qualification of throat thickness for fillet welds

■ Section 5Welder qualification tests

5.1 Scope

5.1.1 The requirements of this Section relate to qualifica-tion of welders involved in welded construction associatedwith ships, or other marine structures, and products or components intended for use on or in these structures.

5.1.2 The requirements relate to fusion welding processesthat are designated as manual, semi-automatic or partlymechanised. Special consideration will be given to other welding processes adapted from these requirements.

5.1.3 Prior to commencing production welding, thewelder is to have performed a qualification test that satisfiesthese requirements. It is the responsibility of the manufacturerto ensure that the welder possesses the required level of skillfor the work to be undertaken.

5.1.4 The qualification of welders is to be documented bythe manufacturer and the records are to be available for reviewby the Surveyor.

5.1.5 Welder qualification tests made in accordance withEN, ISO, JIS, ASME or AWS may be considered for accep-tance provided that, as a minimum, they are equivalent to, andmeet the technical intent of these Rules to the satisfaction ofthe Surveyor.





Alloy designation Former diameter(see Chapter 9) (D/t)

Cast propellers:CU1 4CU2 4CU3 6, see NoteCU4 6, see Note

Other short freezing range castings:Copper-Nickel 90/10 4Copper-Nickel 70/30 4Aluminium bronze 6

Wrought alloys (tubes and pipes):Copper-phosphorus 3Aluminium-brass 390/10 Copper-nickel-iron 370/30 Copper-nickel-iron 3

NOTEWhere the qualification tests for these alloys are subjected to post-weld heat treatment the former diameter may be increased to D/t = 10.

Table 12.4.9 Former diameters for bend testing ofcopper alloy welds

Category

Propellers

Tubes/pipes

Tubes/pipessee Note 2

Alloy grade used in the qualification test

CU1CU2CU3CU4

90/10 Copper-Nickel-Iron


Copper-Phosphorus deoxidised – arsenicalCopper-Phosphorus deoxisised – non arsenicalAluminium-brass

Alloy grades approved

CU1CU1 and CU2CU1, CU2 and CU3CU4 see Note 1


70/30 Copper-Nickel-Iron and90/10 Copper-Nickel-Iron

Copper-Phosphorus deoxidised – arsenicalCopper-Phosphorus deoxisised – non arsenicalAluminium-brass

NOTES1. Where a CU3 type welding consumable has been used for the qualification test, the range of approval may also include welding of CU3. 2. These grades have limited weldability and approval to weld is subject to the materials satisfying the requirements of Table 9.3.1 in

Chapter 9.

Table 12.4.10 Range of approval for copper alloy material grades

5.2.8 The Surveyor may stop the test if the welding conditions are not correct or if there is any doubt about the competence of the welder to achieve the required standard.

5.3 Examination and testing

5.3.1 Each completed test weld is to be examined andtested in accordance with the requirements of Table 12.5.1.

5.3.2 Visual examination is to be performed in the aswelded state prior to any other assessment.

5.3.3 For plate butt welds, fracture testing may be used inplace of radiography.

5.3.4 Where a backing strip has been used, it is to beretained for non-destructive examinations, but is to beremoved prior to performing any bend or fracture tests.

5.3.5 Where fracture tests are required, they are to sampleas much of the inspection length as practicable and the testassembly may be cut into several test specimens to achievethis. Testing is to be performed as shown in Figs. 12.5.1(a) or12.5.1(b).

5.3.6 For butt weld tests in aluminium alloys both radiog-raphy and bend tests are required.

5.3.7 When bend tests are required, 2 root and 2 facebends are to be tested and where the test thickness exceeds12 mm, these may be substituted by 4 side bends specimens.The diameter of former to be used is to be in accordance withthat specified for welding procedure qualification testing givenin 2.7.6(a).

5.3.8 Where macro examination is required, the specimenis to be polished and etched to reveal the weld runs and heataffected zones, and be examined at a magnification betweenx5 and x10.



5.2 Welder qualification test assemblies

5.2.1 The welding of the welder qualification test assemblyis to simulate, as far as practicable, the conditions to be experienced in production and be witnessed by the Surveyor.The test is to be carried out on a test assembly piece and notby way of production welding.

5.2.2 The test is to simulate, as far as practicable, thewelding techniques and practices to be encountered duringproduction welding. The test assembly is to be designed totest the skill of the welder and have the shape and dimensionsappropriate to the range of approval required.

5.2.3 The inspection length of the test weld is to be such asto permit the removal of all the necessary test specimens and forplate tests, but in no case is to be less than 250 mm. The testassembly is to be set in one of the positions as shown in Fig. 12.2.2 appropriate to the welding positions to be approved.

5.2.4 A welding procedure specification (WPS) is requiredfor the execution of the qualification test and is to include theinformation specified in 2.2.1, as a minimum.

5.2.5 The test assembly is to be marked with a uniqueidentification and the inspection length is to be identified priorto commencing welding. For pipe welds, the whole circum-ference is to be considered as the inspection length.

5.2.6 During welding of the test assembly, the weldingtime is to be similar to that expected under production conditions. For manual or semi-automatic processes, at leastone stop and re-start in the root and in the top surface layer isto be included in the inspection length and marked for futureinspection.

5.2.7 During welding of the test assembly, minor imper-fections may be removed by the welder by any method that isused in production, except on the surface layer.


Chapter 12Section 5

Examination type

Visual

Surface crack detection

Radiography

Bend tests

Fracture tests

Macro

Butt welds

100%

See Note 1

100%See Notes 2 and 6

4 requiredSee Notes 3 and 6

Not required

Not required

Fillet welds

100%

100%

Not required

Not required

1 requiredSee Note 4


Pipe branch welds

100%

100%

Not required

Not required

Not required


NOTES1. Surface crack detection examination may be required by the Surveyor in order to clarify the acceptability of any weld feature.2. Radiography may be replaced by ultrasonic examination for carbon and low alloy steels where the thickness exceeds 8 mm.3. Bend tests are required for gas metal arc welding with solid wire (GMAW) and oxy-acetylene welding.4. The fracture test may be replaced with 4 macro sections equally spaced along the inspection length.5. Macro-sections are to be separated by 90° measured around the abutting pipe member.6. Radiography and bend tests are required for tests in aluminium alloys.

Table 12.5.1 Welder qualification test requirements


Welding QualificationsRULES FOR THE MANUFACTURE, TESTING AND CERTIFICATION OF MATERIALS, July 2014

Chapter 12Section 5

Inspection lengthof the test piece

25 mm

25 mm

4607/41

(a)Sectioning into an even-numbered quantity

of test specimens

(b)Fracture testing

(The fillet weld may be notched if necessary)

Fig. 12.5.1(a) Preparation and fracture testing of test specimens for a fillet weld in plate

4607/40

= 2 mm = 2 mm

= 40 mm= 5 mm = 5 mm

Inspection lengthof the test piece

25 mm 25 mml2

l1

l1

(a)Sectioning into an even-numbered quantity of test specimens

(b)Preparation

(c)Fracture testing root bend test

(d)Fracture testing face bend test

Fig. 12.5.1(b) Preparation and fracture testing of test specimens for a butt weld in plate



5.4 Acceptance criteria

5.4.1 The acceptance criteria are to be in accordancewith 2.5.5.

5.4.2 Fracture tests and macro-sections are to beassessed in accordance with the non-destructive examinationacceptance criteria.

5.4.3 Bend tests are considered acceptable if after bendingthrough an angle of at least 180°, there are no defects on thetension side of the specimen greater than 3 mm in any direction.

5.5 Failure to meet requirements

5.5.1 Where a macro-section fails to meet requirements,one additional specimen may be removed from the testassembly and examined.

5.5.2 Where a bend or fracture test specimen fails to meetrequirements, two additional specimens may be prepared fromthe same test assembly. If there is insufficient material, thewelder may be permitted to weld an additional assembly tothe same WPS, at the discretion of the Surveyor.

5.5.3 Where any of the additional test specimens fails tosatisfy the requirements, the test will be considered as notmeeting the requirements.

5.5.4 Where a test fails to comply with the acceptancecriteria, the welder may be permitted to weld a second testpiece. If this does not meet requirements, the welder is to beconsidered as not being capable of achieving the require-ments.

5.6 Range of approval

5.6.1 Upon successful completion of all the necessaryexaminations and tests, the welder is to be considered qualified.The essential variables and the range of welding conditions forwhich the welder is considered approved are specified in thefollowing paragraphs.

5.6.2 Welding variables such as preheat, interpass temperature, heat input and current type are not consideredwelder qualification variables. However, if the WPS used fortesting specify these, they are to be included in the test andthe welder is expected to follow the specific instructions.

5.6.3 Where the WPS used for the welder qualificationtest specifies post weld heat treatment, this need not beapplied to the test weld unless bend tests are required and thematerial exhibits low ductility in the as welded condition.

5.6.4 The qualification test performed by a manufactureris only applicable to workshops under the same technical control and quality system as that used for the test.

5.6.5 The welding process used in the qualification test isthe process approved. However, it is possible for the welder touse more than one process in the test and the range ofapproval that may be applied to each will be within the limitsof the essential variables appropriate to the part of the testwhere each welding process was used.

5.6.6 Material types are to be grouped as shown in Table 12.5.2 for welder qualifications. A qualification test performed on one material from a group will permit welding ofall other materials within the same group. In addition, qualification on one group of materials may confer approval toweld other groups as shown in Table 12.5.3.

5.6.7 A qualification test performed on one thickness willconfer approval to weld other thicknesses as specified in Table 12.5.4. Where welding is required between materials ofdifferent thickness, the reference thickness for approval purposes is to be the lesser thickness.

5.6.8 A qualification test performed on plate confersapproval to weld on pipes having an outside diameter greaterthan 500 mm in a fixed position (see Table 12.5.5 and Table 12.5.6).

5.6.9 A qualification test performed using a specific diameter of pipe will give approval to weld other diameters asshown in Table 12.5.5. For branch welds, the diameter uponwhich approval is based is to be the branch member.

5.6.10 A qualification test performed on a butt weld maybe considered as giving approval for fillet welds.

5.6.11 A butt qualification test welded from one side, withthe root unsupported (i.e., no backing), will give approval forwelds made from both sides with or without back gouging orgrinding, but not vice versa.

5.6.12 A qualification test performed in one position will giveapproval to weld in other positions as shown in Table 12.5.6.

5.6.13 For manual metal arc welding with covered electrodes, a qualification test performed using an electrodewith one type of coating will only be approved for welding withthat type of coating. However, a qualification test performedusing a basic low hydrogen type coating will confer approvalto use electrodes with rutile coatings.

5.6.14 For gas shielded welding processes that use a single component shielding gas, no change to the gas composition is permitted from that tested. Where the test hasused a two component shielding gas, a change in the ratio ofcomponent gases is permitted, provided that one of the components is not reduced to zero. Where the test has useda three component shielding gas, changes are permitted in theratio of component gases and the gas with the smallest ratiomay be reduced to zero, provided this does not change theshielding gas from an active one to an inert one or vice versa.In addition, where a change in shielding gas compositionrequires a different welding method or technique to beemployed, a new qualification test will be required.

5.6.15 A change of welding flux from that used for the testis permitted.


Chapter 12Section 5



5.7 Welders qualification certification

5.7.1 All the relevant conditions used during the test areto be entered on the welder’s qualification certificate alongwith the permitted range of approval.

5.7.2 If the Surveyor is satisfied that the welder hasdemonstrated the appropriate level of skill and all tests are satisfactory, the Surveyor will endorse the certificate verifyingthat the details contained on it are correct and that the testwelds were prepared, welded and tested in accordance withthe specified Rules, Codes or Standards.

5.7.3 The welder is considered to be approved for an initialvalidity period of 2 years. The welder is considered to haveretained the qualification subject to the manufacturer confirmingevery 6 months that the welder has used the welding processwith acceptable performance in the preceding 6 months.

5.7.4 After 2 years, the Surveyor may extend the validityof the approval for another period of two years provided thatrecords or documented evidence is made available confirmingacceptable welding performance, within the original range ofapproval, without a break exceeding 6 months. The Surveyorwill signify acceptance of the extension to the validity byendorsing the certificate.


Chapter 12Section 5

Material group

WQ 01

WQ 02

WQ 03

WQ 04

WQ 05

WQ 011

WQ 22a

WQ 22b

WQ 23

WQ 30

WQ 31

WQ 32

WQ 33

WQ 34

WQ 35

WQ 36

Material description

Low carbon unalloyed,C/Mn, or Low alloyed steels (Re ≤ 360 N/mm2)

Cr-Mo, orCr-Mo-V creep resisting steels

High strength fine grained,Normalised or quenched, or Tempered structural steels (2,0 – 5%Ni, with Re > 360 N/mm2)

Ferritic, ormartensitic stainless steels (12 to 20% Cr)

Ferritic low temperature steels

Ferritic-austenitic stainless steels,Austenitic stainless steels, orCr-Ni steels

Aluminium alloy – Non-heat treatableMg < 3,5%

Aluminium alloy – Non-heat treatable 3,5% < Mg < 5,6%

Aluminium alloy – Heat treatable

Copper alloys for propellers –Manganese bronze

Copper alloys for propellers – Nickel-manganese bronze

Copper alloys for propellers – Nickel-aluminium bronze

Copper alloys for propellers –Manganese-aluminium bronze

Copper alloys for tubes – Copperphosphorus

Copper alloys for tubes – Aluminiumbrass

Copper alloys for tubes – Copper-nickel-iron

Typical LR Grades

A, B, D and EAH to FH32 and 36Boiler 510FG and lowerLT-AH to FH32 and 36U1 and U2Steel castingsSteel pipes

13CrMo45 and 11CrMo9101Cr½Mo and 2¼Cr1Mo½Cr½Mo¼V

AH to FH40 to 69LT-AH to LT-FH401½ , 3½ Ni steels and castingsU3, R3, R3S and R4

13% Cr (martensitic)

5Ni and 9Ni

304, 316, 317, 321 and 347S31260, S31803, S32550 andS32750

5754

5083 and 5086

6005-A, 6061 and 6082

Cu1

Cu2

Cu3

Cu4

Deoxidised – non-arsenical andarsenical

Aluminium brass

70/30 Cu/Ni and 90/10 Cu/Ni

Rules for Material references

Ch 3,2Ch 3,3Ch 3,4Ch 3,6Ch 3,9 and Ch 10Ch 4,2, 3, 6 and 7Ch 6,2, 3, 4 and 6

Ch 3,4Ch 4,6 and Ch 6,2, 3 and 6Ch 4,6 and Ch 6,2

Ch 3,3 and 10Ch 3,6Ch 3,6, Ch 4,7 and Ch 6,4Ch 3,9 and Ch 10

Ch 4,5 (martensitic)

Ch 3,6

Ch 3,7 and 8Ch 4,8 and Ch 6,5

Chapter 8

Chapter 8

Chapter 8

Ch 9,1

Ch 9,1

Ch 9,1

Ch 9,1

Ch 9,3

Ch 9,3

Ch 9,3

Table 12.5.2 Welder qualification materials groupings




Material type

Steel and copper alloys

Aluminium alloys

Test piece diameter(mm)

D ≤ 2525 < D ≤ 150

D > 150Plate, see Note 2

D ≤ 125D > 125

Plate, see Note 2

Range approved(mm)

D to 2D0,5D to 2D, see Note 1

≥ 0,5D≥ 500

0,25D to 2D≥ 0,5D≥ 500

NOTES1. Subject to 25 mm minimum diameter.2. Plate qualification will approve welding on pipes greater than 150 mm diameter when the pipe is rotated.

Table 12.5.5 Welder qualification, diameter range of approval for pipes and hollow sections

Material group used for testing Material groups approved to weld

WQ 01

WQ 02

WQ 03

WQ 04

WQ 05

WQ 11

WQ 22a

WQ 22b

WQ 23

WQ 30

WQ 31

WQ 32

WQ 33

WQ 34

WQ 35

WQ 36

WQ 01

WQ 01

WQ 01

WQ 01

WQ 05

WQ 11

WQ 22a

WQ 22a

WQ 22a

WQ 30

WQ 30

WQ 30

WQ 30

WQ 34

WQ 34

WQ 36

WQ 02

WQ 02

WQ 02

WQ 05, see Note

WQ 22b

WQ 22b

WQ 22b

WQ 31

WQ 31

WQ 31

WQ 31

WQ 35

WQ 35

WQ 03

WQ 04

WQ 04, see Note

WQ 23

WQ 32

WQ 32

WQ 32

WQ 32

WQ 33

WQ 33

WQ 33

WQ 33

NOTEProvided an austenitic welding consumable compatible with material group WQ 11 is used.

Table 12.5.3 Welder qualification, range of approval for material groups

Material type

Steel and copper alloys

Aluminium alloys

Test piece thickness(mm)

t ≤ 33 < t ≤ 12

t > 12

t ≤ 66 < t ≤ 15t > 40 mm

Range approved, see Note(mm)

t to 2t3,0 to 2t

≥ 5,0

0,7 to 2,5t6,0 < t ≤ 40,0

41 to 2t

NOTEFor oxy-acetylene welding the maximum thickness is limited to 1,5 t.

Table 12.5.4 Welder qualification, range of approval for material thickness

5.7.5 Where there is any reason to question the welder’sability, or there is a lack of continuity in the use of the weldingprocess, or insufficient recorded evidence of acceptable weldperformance, the welder is to perform a new qualification test.

5.7.6 Where the manufacturer has existing welders thathave previously performed qualification tests, these may beconsidered for acceptance provided they satisfy the aboverequirements and the tests have been performed in the presence of an independent examiner that is acceptable to theSociety.

5.7.7 Not withstanding the above, the Surveyor may atany time request a review of a welder’s qualification records. Ifthere is any reason for doubt concerning the skill of the welder,the Surveyor may withdraw the qualification and require a re-qualification test to be performed.


Chapter 12Section 5



Test weld conditions Positions qualified

Test position

D

X

Vu

Vd

O

D

X

Vu

Vd

O

D

X

D+Vu+O,see Note 3

D+Vd+O,see Notes 2 and 3

Axis at 45°,see Note 4,

Travel Vu

Axis at 45°,see Notes 2, 3 and 4,

Travel Vd

D

X

D+Vu+Osee Note 3

D+Vd+Osee Note 3

Type of weld

Plate butt,see Note 5

Plate Fillet,see Note 5

Pipe butt

Pipe fillet

Plate Pipe, see Note 1

Butt weld

D

D,X

D, Vu

Vd

D, X, Vu, O

—

—

—

—

—

D

D, X

D, Vu, O

Vd

D, X, Vu, O

Vd

—

—

—

—

Fillet weld

D

D, X

D, X, Vu

Vd

D, X, Vu, O

D

D, X

D, X, Vu

Vd

D, X, Vu, O

D, X

D, X

D, X, Vu, O

Vd

D, X, Vu, O

Vd

D

D, X

D, X, Vu, O

Vd

Butt weld

D

D

D

—

D

—

—

—

—

—

D

D, X

D, Vu, O

Vd

D, X, Vu, O

Vd

—

—

—

—

Fillet weld

D

D, X

D, Vu

—

D, X, Vu, O

D

D, X

D, X, Vu

—

D, X, Vu, O

D, X

D, X

D, X, Vu, O

Vd

D, X, Vu, O

Vd

D

D, X

D, X, Vu, O

Vd

NOTES1. Pipe D position means pipe in horizontal position and rotated, see Fig. 12.2.2(b) and Fig. 12.2.2(d).2. Vd position not usually recommended for pipe welds less than 500 mm diameter.3. Pipe fixed with axis in the horizontal position (e.g. ASME 5G).4. Pipe fixed with axis at 45° to the horizontal (e.g. ASME 6G).5. Plate qualification tests confers approval to weld pipes with diameter greater than 500 mm.

Table 12.5.6 Welding position ranges for welder qualification

■ Section 6Qualification of friction stir welding of aluminium alloys

6.1 Scope

6.1.1 The requirements of this Section relate to theFriction Stir Welding (FSW) of aluminium alloys. Theserequirements include requirements for verification of weldingequipment, welding procedures, qualification of weldingprocedures and qualification of welding operators.

6.2 Welding equipment

6.2.1 Welding equipment (e.g., welding machines andFSW tools) is to be capable of producing welds that meet thespecified acceptance levels.

6.2.2 Welding equipment is to be maintained in a goodcondition and is to be repaired or adjusted when necessary.

6.2.3 After installation of new or refurbished equipment,appropriate tests are to be performed to verify that the equip-ment functions correctly.

6.3 Weld procedures

6.3.1 This Section defines the requirements for weldingprocedures to be applied for FSW of aluminium alloys.

6.3.2 Manufacturers are to prepare a preliminary weldingprocedure specification (pWPS) defining procedures for howFSW is to be conducted.

6.3.3 A pWPS is to comply with the requirements of ISO25239-4.

6.3.4 Qualification of a pWPS is achieved by conductingweld procedure qualification tests in accordance with ISO25239-4. Minimum acceptance criteria for destructive testsare to be in accordance with these Rules. Reporting of thequalification tests are to be in accordance with ISO 25239-4.

6.3.5 Provided that the procedure qualification recordlists all the relevant variables and there are no inconsistentfeatures and the results satisfy the requirements, the procedurequalification record may be endorsed by the Surveyor assatisfying the requirement of the Rules.

6.3.6 A welding procedure specification (WPS) is to beprepared after the procedure qualification test report has beenendorsed by the Surveyor.

6.3.7 For welding procedure specifications, the range ofapproval is to be limited as follows:(a) Manufacturer. A welding procedure qualified by a

manufacturer is valid for welding in workshops under thesame technical and quality management.

(b) Range of material type. Approval is restricted to thespecific aluminium grade and supply condition used inthe qualification test.

(c) Thickness. Approval is restricted to the thickness of thetest piece in the qualification test.

(d) Joint types. The joint types approved are to be thosefrom the welding procedure qualification test only.

(e) Welding tool. Approval is restricted to the specificdesign of welding tool employed during the qualificationtest.

(f) Other. A range of approval for any other variables will besubject to special consideration.

6.4 Qualification of welding operators

6.4.1 Welding operators are to be qualified in accordancewith ISO 25239-3.

6.4.2 Welding operators are to be suitably trained and willbe required to demonstrate a knowledge of FSW and have aworking knowledge of the welding installation. Knowledge ofthe FSW process may be demonstrated by exams passedduring the training period. Demonstration of a working knowledge of the welding installation will be subject to theSurveyor’s satisfaction.

6.4.3 Qualification of welding operators is to be by weldingtests as specified in ISO 25239-3 or by conducting weldprocedure qualification tests.

6.4.4 Upon successful completion of all necessary exam-ination and tests, the welding operator is to be consideredqualified. The range of qualification is to be as specified in ISO25239-3.

6.4.5 A certificate of qualification is to be issued in accor-dance with ISO 25239-3.




Section

1 General welding requirements

2 Specific requirements for ship hull structure andmachinery

3 Specific requirements for fabricated steel sections

4 Specific requirements for fusion welded pressure vessels

5 Specific requirements for pressure pipework

6 Repair of existing ships by welding

7 Austenitic and duplex stainless steel – Specificrequirements

8 Specific requirements for welded aluminium

9 Friction stir welding requirements for aluminiumalloys

■ Section 1General welding requirements

1.1 Scope

1.1.1 This Chapter specifies requirements for fabricationand welding during construction and repair of ships or othermarine structures, and their associated pressure vessels,machinery, equipment, components and products intendedfor use in these structures.

1.1.2 The requirements for fabrication and welding duringconstruction and repair of tanks intended for transport or storage of liquefied gases are located in the Rules andRegulations for the Construction and Classification of Ships forthe Carriage of Liquefied Gases in Bulk or the Rules andRegulations for the Classification of a Floating OffshoreInstallation at a Fixed Location, as appropriate.

1.1.3 The requirements relate to fusion welding. Specialconsideration will be given to the use of other welding processes based on these requirements.

1.1.4 It is the responsibility of the manufacturer to ensurecompliance with all aspects of these Rules and inform theSurveyor of any deviations that have occurred. All deviationsare to be recorded as non-compliances along with the corrective actions taken and failure to do this is considered torender the fabrication to be in non-compliance with the Rules.

1.1.5 Welded constructions that comply with National orInternational specifications may be accepted to the satisfac-tion of the surveyor, provided that these specifications givereasonable equivalence to the requirements of this Chapter.

1.1.6 All welded construction is to be to the satisfaction ofthe Surveyor.

1.2 Design

1.2.1 Prior to commencing any work, the component tobe manufactured is to be subjected to design review andapproval in accordance with the Rule requirements.

1.2.2 The material characteristics that are affected bywelding, particularly the loss of strength (e.g., in precipitationor strain hardened aluminium alloys) are to be considered inthe design. The weld joints in such materials are to bearranged such that they are in areas of lower stress.

1.3 Materials

1.3.1 Materials used in welded construction are to bemanufactured at works approved by LR. The use of materialsfrom alternative sources will be subject to agreement of theSurveyor and satisfactory verification testing.

1.3.2 Materials are to be supplied and certified in accor-dance with the requirements of Chapters 1 to 10 of theseRules.

1.3.3 Materials used in welded construction are to bereadily weldable and are to have proven weldability, unlessrequirements are agreed with LR in advance.

1.3.4 Where the construction details are such that materialsare subject to through-thickness strains, consideration is to begiven to using material with specified through-thickness properties as specified in Ch 3,8.

1.3.5 When ordering materials for construction, consider-ation is to be taken of the possible degradation of propertiesduring fabrication or post-weld heat treatment. Where thesematerials are used, consideration is to be given to additionaltest requirements being specified to the supplier.

1.3.6 The identity of materials is to be established by wayof markings etc, during fabrication, so that traceability to theoriginal manufacturer’s certificate is maintained.

1.3.7 Pre-fabrication shop primers may be applied priorto welding, provided that they are of an approved type andhave been tested to demonstrate that they have no deleteriouseffects on the completed weld.

1.3.8 Where it is proposed to weld forgings and/or castings,full details of the joint details, welding procedures and post-weld heat treatments are to be submitted for consideration.

1.4 Requirements for manufacture and workmanship

1.4.1 The welding workshops are to be assessed by theSurveyor for their capability to produce work of the requiredquality in accordance with the requirements specified for thetype of construction, see Sections 2 to 5.


Requirements for Welded Construction Chapter 13Section 1


1.6 Forming and bending

1.6.1 Plates, pipes, etc., may be formed to the requiredshape by any process which does not impair the quality of thematerial.

1.6.2 Where hot forming is employed or during cold formingwhere the material is subjected to a permanent strain exceeding 10 per cent or formed to a diameter to thicknessratio less than 10, tests are required to be performed todemonstrate that the material properties remain acceptable.

1.6.3 As far as practicable, forming is to be performed bythe application of steady continuous loading using a machinedesigned for that purpose. The use of hammering, in either thehot or cold condition is not to be employed.

1.6.4 Material may be welded prior to forming or bending,provided that it can be demonstrated that the weld mechanicalproperties are not impaired by the forming operation. All weldssubjected to bending are to be inspected on completion toensure freedom from surface breaking defects.

1.7 Assembly and preparation for welding

1.7.1 Excessive force is not to be used in fairing and closing the work. Where excessive root gaps exist betweensurfaces or edges to be joined, corrective measures are to beadopted.

1.7.2 Provision is to be made for retaining correct alignmentduring welding operations in accordance with the approvedmanufacturing specifications and welding procedures.

1.7.3 Tack welds are to be avoided as far as practicable.When used, tack welds are to be of the same quality as thefinished welds, made in accordance with approved weldingprocedures, and where they are to be retained as part of thefinished weld, they are to be clean and free from defects.

1.7.4 Generally, tack welds are not to be applied inlengths of less than 30 mm for mild steel grades and aluminiumalloys, and 50 mm for higher tensile steel grades. Smaller tackwelds may be accepted for steels, provided that the carbon equivalent of the materials being welded is not greaterthan 0,36 per cent.

1.7.5 Where deep penetration welding is used (see 2.4.6),welding procedure tests are to demonstrate that the specifieddegree of penetration is achieved in way of tack welds left inplace.

1.7.6 Where temporary bridge pieces or strong-backs areused, they are to be of similar materials to the base materialsand welded in accordance with approved welding procedures.

1.7.7 Any fit-up aids and tack welds, where welded toclad materials, are to be attached to the base material and notto the cladding.

1.4.2 Where structural components are to be assembledand welded in works sub-contracted by the builder, theSurveyor is to inspect the sub-contractor’s works to ensure thatcompliance with the requirements of this Chapter is achieved.

1.4.3 The manufacturer is to provide a system of regularsupervision of all welding, by suitably qualified and experiencedpersonnel.

1.4.4 Welding is to be performed in covered workshopsas far as practicable. Where this is not possible, provision is tobe made in the welding area to give adequate protection fromwind, rain and cold, etc.

1.4.5 Where required, arrangements are to be such as topermit adequate ventilation and access for preheating, and forthe satisfactory completion of all welding operations.

1.4.6 The location of welding connections and sequencesof welding are to be arranged to minimise distortion and thebuild up of residual stresses. Welded joints are to be soarranged as to facilitate the use of downhand welding wherever possible.

1.4.7 In the case of repairs to existing structures or components, care is to be exercised when attaching fit-upaids by welding to ensure that the base materials in way of theattachments are of weldable quality.

1.4.8 In order to prevent cross-contamination of differentmaterial types, the welding of carbon steel materials is to be inareas segregated from that used for either austenitic or non-ferrous materials, see Section 7.

1.5 Cutting of materials

1.5.1 Materials may be cut to the required dimensions bythermal means, shearing or machining in accordance with themanufacturing drawings or specifications.

1.5.2 Cold shearing is not to be used on materials inexcess of 25 mm thick. Where used, the cut edges that are toremain un-welded are to be cut back by machining or grindingfor a minimum distance of 3 mm.

1.5.3 Material, which has been thermally cut, is to be freefrom excessive oxides, scale and notches.

1.5.4 All cut edges are to be examined to ensure freedomfrom material and/or cutting defects. Visual examination maybe supplemented by other techniques.

1.5.5 Thermal cutting of alloy and high carbon steels mayrequire the application of preheat, and special examination ofthese cut edges will be required to ensure no cracking. Inthese cases, the cut edge is to be machined or ground backa distance of at least 2 mm, unless it has been demonstratedthat the cutting process has not damaged the material.

1.5.6 Any material damaged in the process of cutting is tobe removed by machining, grinding or chipping back to soundmetal. Weld repair may only be performed with the agreementof the Surveyor.



LLOYD’S REGISTER2

1.9.4 All welders and welding operators are to be qualifiedin accordance with the requirements of Chapter 12.Qualification records to demonstrate that welding personnelhave the skills to achieve the required standard of workman-ship are to be available to the Surveyor.

1.10 Welding during construction

1.10.1 Materials to be assembled for welding are to beretained in position by suitable means such that the root gapsand alignment are in accordance with the approved manufac-turing specifications and welding procedures.

1.10.2 Surfaces of all parts to be welded, are to be clean,dry and reasonably free from rust, scale and grease.

1.10.3 Pre-heat is to be applied, as specified in theapproved welding procedure, for a distance of at least 75 mm from the joint preparation edges. The method of application and temperature control are to be such as to maintain the required level throughout the welding operation.

1.10.4 When the ambient temperature is 0°C or less, orwhere moisture resides on the surfaces to be welded, duecare is to be taken to pre-heat the joint to a minimum of 20°C, unless a higher pre-heat temperature is specified.

1.10.5 Where tack welds are to be removed from the rootof the weld joint, this is to be carried out such that the surrounding material and joint preparation is not damaged.

1.10.6 The welding arc is to be struck on the parent metalwhich forms part of the weld joint or on previously depositedweld metal.

1.10.7 Where the welding process used is slag forming(e.g., manual metal arc, submerged arc, etc.) each run ofdeposit is to be cleaned and free from slag before the next runis applied.

1.10.8 Full penetration welds are to be made from bothsides of the joint as far as practicable. Prior to welding the second side, the weld root is to be cleaned, in accordancewith the requirements of the approved welding procedure, toensure freedom from defects. When air-arc gouging is used,care is to be taken to ensure that the ensuing groove is slagand oxide free and has a profile suitable for welding.

1.10.9 Where welding from one side only, care is to beexercised to ensure the root gap is in accordance with theapproved welding procedure and the root is properly fused.

1.10.10 Particular care is to be exercised in welding in thevertical position with direction of travel downward (Vd) to avoidwelding defects. The use of solid wire gas metal arc (GMAW)process in the vertical down position is to be avoided.

1.10.11 Welding is to proceed systematically with eachwelded joint being completed in correct sequence withoutundue interruption.

1.7.8 Surfaces of all parts to be welded, are to be clean,dry and free from rust, grease, debris and other forms of contamination.

1.7.9 When misalignment of structural members eitherside of bulkheads, decks etc., exceeds the agreed tolerance,the misaligned item is to be released, realigned and re-weldedin accordance with an approved procedure.

1.8 Welding equipment and welding consumables

1.8.1 Welding plant and equipment is to be suitable forthe purpose intended and properly maintained, taking intoaccount relevant safety precautions.

1.8.2 Suitable means of measuring the welding parameters(i.e. current, voltage and travel speed) are to be available.Electrical meters are to be properly maintained and have current calibrations.

1.8.3 Welding consumables are to be suitable for the typeof joint and grade of material to be welded, and in general, areto be LR Approved in accordance with Chapter 11.

1.8.4 Special care is to be taken in the distribution, storageand handling of all welding consumables. They are to be keptin heated dry storage areas with a relatively uniform tempera-ture in accordance with the consumable manufacturer’s recommendations. Condensation on the metal surface (e.g.,wire electrodes and studs) during storage and use is to beavoided.

1.8.5 Prior to use, welding consumables are to be driedand/or baked in accordance with the consumable manufac-turer’s recommendations.

1.8.6 Satisfactory storage and handling facilities for consumables are to be provided close to working areas andthe condition of welding consumables are to be subject to regular inspections.

1.9 Welding procedure and welder qualifications

1.9.1 Welding procedures are to be developed by themanufacturer for all welding, include weld repairs, and are tobe capable of achieving the mechanical property requirementsand non-destructive examination quality appropriate to thework being undertaken.

1.9.2 Welding procedures are to be established for thewelding of all joints and are to be qualified by testing in accor-dance with Chapter 12. The welding procedures are to givedetails of the welding process, type of consumable, jointpreparation, welding position and filler metals to be used.

1.9.3 The proposed welding procedures are to beapproved by the Surveyor prior to construction.




1.10.12 After welding has been stopped for any reason,care is to be taken in restarting to ensure that the previouslydeposited weld metal is thoroughly cleaned of slag and debris,and preheat has been re-established.

1.10.13 Care is to be taken to avoid stress concentrationssuch as sharp corners or abrupt changes of section, andcompleted welds are to have an even contour, blendingsmoothly with the base materials. The weld shape and size isto be in accordance with that specified in the approved drawings or specifications.

1.10.14 Welded temporary attachments used to aid construction are to be removed carefully by grinding, cuttingor chipping. The surface of the material is to be finishedsmooth by grinding followed by crack detection.

1.10.15 Where fabricated and welded components requireto be machined, all major welding operations are to be completed prior to final machining.

1.10.16 Welding to parts which are subjected to rotatingfatigue (e.g., shafts) is not generally permitted.

1.10.17 Welding onto parts that have been hardened forwear resistance or strength (e.g., gear teeth) is not permitted.

1.10.18 Where welding of clad ferritic steel plates is to beundertaken, the clad materials are to be ground back from theprepared edge by at least 10 mm. In general, the ferritic materials are to be welded prior to welding of the claddingmaterial.

1.11 Non-destructive examination of welds

1.11.1 Non-destructive examinations are to be made inaccordance with a definitive written procedure prepared andendorsed by a person qualified according to a NationallyRecognised Scheme with a grade equivalent to Level III qualification of ISO 9712, SNT-TC-1A, or ASNT CentralCertification Program (ACCP). As a minimum, the procedurewill identify personnel qualification levels, NDE datum and identification system, extent of testing, methods to be appliedwith technique sheets, acceptance criteria and reportingrequirements. These procedures are to be reviewed by theSurveyor. See Ch 1,5.

1.11.2 Non-destructive examinations are to be undertakenby personnel qualified according to a Nationally RecognisedScheme with a grade equivalent to Level II qualification of ISO 9712, SNT-TC-1A or ASNT Central Certification Program(ACCP). Operators qualified to Level I of the above schemes(or equivalent recognised by LR) may be engaged in testingunder the supervision of personnel qualified to Level II or III (orequivalent recognised by LR). Personnel qualifications are tobe verified by certification.

1.11.3 Effective arrangements are to be provided by themanufacturer for the inspection of finished welds to ensurethat all welding, and where necessary, all post-weld heat treatment, has been satisfactorily completed.

1.11.4 Welds are to be clean and free from paint at thetime of visual inspection unless specified otherwise in the following Sections.

1.11.5 The weld surface finish is to ensure accurate andreliable detection of defects. Where the weld surface is irregularor has other features likely to interfere with the interpretation ofnon-destructive examination, the weld is to be ground ormachined.

1.11.6 Prior to inspection, welded temporary attachmentsand lifting eyes used to aid construction are to be removedcarefully by grinding, cutting or chipping or other approvedmeans. The surface of the material is to be finished smooth bygrinding followed by crack detection. Any defects caused inthe removal process are to be repaired and re-inspected.

1.11.7 For welds in steels with specified yield strength upto 400 N/mm2, and with carbon equivalent less than or equalto 0,41 per cent, NDE may be performed as soon as the testassembly has cooled to ambient temperature. For othersteels, NDE is to be delayed for a period of at least 48 hoursafter the test assembly has cooled to ambient temperature.

1.11.8 Non-destructive examinations are to be performedin accordance with the requirements of the Rules.Examinations are to be in accordance with agreed written procedures prepared by the manufacturer or ship builder.

1.11.9 The Surveyor may request additional inspectionswhere there is reason to question the quality of workmanship,or where the weld is part of a complicated fabrication wherethere is high restraint or high residual stresses.

1.11.10 Welds are to be examined after completion of anypost-weld heat treatment.

1.11.11 Where weld defects are discovered, the full extent isto be ascertained by applying additional non-destructiveexaminations where required. Unacceptable defects are to becompletely removed and, where necessary, weld repaired inaccordance with the relevant Sections of this Chapter. Therepairs are to be re-inspected using the same technique as theoriginal inspection.

1.11.12 Results of non-destructive examinations are to berecorded and evaluated by the constructor on a continualbasis in order that the quality of welding can be monitored.These records are to be available to the Surveyor.

1.11.13 The constructor is to be responsible for the review,interpretation, evaluation and acceptance of the results ofNDE. Reports stating compliance or otherwise with the criteria established in the inspection procedure are to beissued. Reports are to comply, as a minimum, with therequirements of Ch 1,5.

1.11.14 The extent of applied non-destructive examinationis to be increased when warranted by the analysis of previousresults.



LLOYD’S REGISTER4

1.12 Routine weld tests

1.12.1 Routine or production weld tests may be specifiedas a means of monitoring the quality of the welded joints. Thistype of quality control test is generally specified for pressurevessel and LNG construction but may be used for other typesof welded fabrication.

1.12.2 Routine weld tests may be requested by theSurveyor where there is reason to doubt the quality of work-manship.

1.12.3 Where routine test welds have been agreed, they areto be performed in accordance with the general requirementsfor the type of construction, see Sections 3 and 4.

1.13 Rectification of material defects

1.13.1 Repair of defects found in base materials is not tobe carried out without the prior approval of the Surveyor.

1.13.2 In general, surface defects in the material may beremoved by grinding, chipping, etc., provided the remainingmaterial thickness is not reduced below the minimum thickness tolerance, and the area is ground to blend insmoothly with the surrounding material.

1.13.3 Confirmation that the defect has been removed isrequired by performing visual examination, augmented by eithermagnetic particle or dye penetrant examination techniques.

1.13.4 Surface defects, which cannot be repaired by theabove method, may be repaired by welding where permittedby Chapters 3 to 9. Such repairs are to be performed in accor-dance with the requirements of this Section and those specified in Chapters 3 to 9.

1.13.5 Any defects in the structure resulting from theremoval of temporary attachments are to be prepared, efficiently welded and ground smooth so as to achieve adefect free repair.

1.14 Rectification of distortion

1.14.1 Fairing, by linear or spot heating, to correct distor-tions due to welding, may be carried out. In order to ensurethat the properties of the material are not adversely affected,approved procedures are to be utilised. On completion ofsuch processes, visual examination of all heat affected areasin the vicinity is to be carried out to ensure freedom fromcracking.

1.14.2 When misalignment of members exceeds theagreed tolerance, the misaligned item is to be cut apart,realigned and re-welded in accordance with an approved procedure.

1.15 Rectification of welds defects

1.15.1 Where repairs are extensive the manufacturer is toinvestigate the reason for the defects and take the necessaryactions to prevent recurrence. In addition, consideration is tobe given to the sequence of repairs and to providing temporarysupports to prevent misalignment or collapse.

1.15.2 Cracks are to be reported to the Surveyor and thecause established prior to undertaking weld repairs.

1.15.3 Defects may be removed by grinding, chipping orthermal gouging. Where thermal gouging is used, the repairgroove is to be subsequently ground clean to remove oxidesand debris. The groove is to have a profile suitable for welding.

1.15.4 Prior to commencing repair welding, it is to be confirmed that no defect exists on the prepared surface byperforming visual examination, augmented by either magneticparticle or dye penetrant examination techniques.

1.15.5 Repair welding is to be performed using approvedwelding procedures.

1.15.6 Completed repairs are to be re-examined by thenon-destructive examination method(s) that detected the original defect and are to confirm that the original defect hasbeen removed.

1.15.7 Where the component or structure has been subjected to post-weld heat treatment prior to weld repair, thisis to be repeated after completion of all repair welding.

1.15.8 Where non-destructive examination reveals that theoriginal defect has not been successfully removed, one morerepair attempt may be performed.

1.15.9 The manufacturer is to monitor the quality of weldingand maintain records of welding repairs and take the necessarycorrective actions where repair rates are outside normal limits.

1.16 Post-weld heat treatment

1.16.1 On completion of welding, post-weld heat treatmentmay be required depending on the type of welded construction, the material type and thickness as specified bythe relevant Parts or Sections of the Rules.

1.16.2 In general, heat treatment after welding is to be astress relief treatment in order to reduce residual stressesintroduced by welding and is generally applicable to ferriticsteels. Where other types of heat treatment (e.g., normalising,solution annealing) are proposed, demonstration of accept-able mechanical properties of the weldment are to be confirmed by a welding procedure test which includes a simulated heat treatment.

1.16.3 Parts are to be properly prepared for heat treat-ment. Machined surfaces (e.g., flange faces, screw threads,etc.) are to be protected against scaling and sufficient temporary supports provided to prevent distortion or collapseof the structure.




1.16.4 Details of the heat treatment to be applied, soakingtime and temperature, heating and cooling rates, etc., are tobe submitted for review prior to commencing.

1.16.5 Post-weld heat treatment is to be carried out in apurpose built furnace which is efficiently maintained. In specialcases, where the configuration of the component is such thatthermal stresses during heating and cooling can be minimised,local post-weld heat treatment may be used. This would notnormally apply to the complex geometry of cast materials during manufacture within the foundry environment.

1.16.6 In all cases, the heat treatment facilities andarrangements are to be capable of controlling the temperaturethroughout the heat treatment cycle and adequate means ofmeasuring and recording the component temperature are tobe provided. Thermocouples are to be attached so they are incontact with the component.

1.16.7 Unless specified otherwise, stress relief heat treat-ment is to be carried out by means of controlled heating from300°C, to the soak temperature, holding within the prescribedsoaking temperature range for the time specified (usually 1 hour per 25 mm of weld thickness) followed by controlledcooling to below 300°C.

1.16.8 Where post-weld stress relief is specified for weldedconstructions that contain joints between different materials(e.g. ferritic to austenitic steels), the details of the materials,welding procedures and heat treatment cycle to be applied areto be submitted for special consideration and approval.

1.16.9 Non-destructive examination of welds is to be performed after completion of any heat treatment.

1.17 Certification

1.17.1 Products or components are not to be consideredcomplete until all the requirements of the construction specifi-cation have been met and all activities have been completed.

1.17.2 Upon completion of the works, the manufacturer isto provide documentation which indicates that:(a) All welds are complete and there are no outstanding

repairs.(b) The appropriate post-weld heat treatments have been

performed.(c) Appropriate destructive tests have been performed.(d) Proof testing of welds has been performed.

1.17.3 Before the test certificates or shipping statementsare signed by the Surveyor, the manufacturer is required toprovide a written declaration stating that the product is inaccordance with the requirements of 1.17.2.

■ Section 2Specific requirements for ship hullstructure and machinery

2.1 Scope

2.1.1 The requirements of this Section apply to theconstruction of ships, including hull structure, superstructureand deckhouses, components forming part of the ship structure and its machinery (excluding pressure equipmentand piping, see Section 4). These requirements are in additionto the general welding requirements specified in Section 1.

2.1.2 The shipyard and manufacturer’s works are to beassessed to give assurance that they have the facilities,equipment, personnel and quality control procedures toproduce work of the required quality.

2.2 Welding consumables

2.2.1 Welding consumables used for hull construction areto be approved in accordance with Chapter 11 and are to besuitable for the type of joint and grade of material to bewelded.

2.2.2 Steel welding consumable approvals, up to andincluding Grade Y40 and Y47, are considered acceptable forhull construction in line with Table 11.1.1 in Chapter 11, Ch 12,2.2.2 and the following:(a) Consumables up to Grade Y are acceptable for welding

steels up to 3 strength levels below that for which theapproval applies, e.g., a consumable with approval grading 3Y is acceptable for welding EH36, EH32 andEH27S higher tensile ship steels and grade E normalstrength ship steel.

(b) Consumables for Grade Y40 are acceptable for weldingsteels up to two strength levels below that for which theapproval applies. Consumables for Grade Y47 areacceptable for welding steels up to one strength levelbelow that for which the approval applies.

(c) Consumables with an approved impact toughness grading are acceptable for welding steels with lowerspecified impact properties subject to (a) above, e.g. aconsumable with approval grading 3Y is acceptable forwelding EH, DH and AH materials.

(d) For welding steels of different grades or different strengthlevels, the welding consumables may be of a type suitable for the lesser grade or strength beingconnected. The use of a higher grade of weldingconsumable may be required at discontinuities or otherpoints of stress concentration.

2.2.3 In general, the use of preheating and hydrogencontrolled welding consumables for welding of ship steels upto strength grade H40 is to be in accordance with Table 13.2.1. The carbon equivalent is to be calculated fromthe ladle analysis using the formula given below:

Carbon equivalent = C + + +

Preheat and the use of low hydrogen controlled consumableswill be required for welding of steel grades higher than Grade H40.

Mn6

Cr + Mo + V5

NI + Cu15


Requirements for Welded Construction Chapter 13Sections 1 & 2

LLOYD’S REGISTER6

2.2.4 All aluminium alloy welding consumables are to beapproved in accordance with Chapter 11 and are suitable forwelding the grades of material as shown in Table 13.2.2.

2.2.5 All austenitic stainless steel and duplex stainlesssteel welding consumables are to be approved in accordancewith the Chapter 11 and are suitable for welding the grades ofmaterial as shown in Table 13.2.3.

2.3 Welding procedure and welder qualifications

2.3.1 Welding procedures and welder qualifications areto be tested and approved in accordance with the require-ments of Chapter 12.

2.4 Construction and workmanship

2.4.1 Weld preparations and openings may be formed bythermal cutting, machining or chipping. Chipped surfaces thatwill not be subsequently covered by weld metal are to beground smooth.

2.4.2 Prior to welding, the alignment of plates and stiffeners forming part of the hull structure is to be in accor-dance with the tolerances specified in the relevant part of theRules.

2.4.3 When welding from one side only, care is to beexercised to ensure the root gap and fit up are in accordancewith the approved welding procedure and the root is properlyfused.

2.4.4 Where it is proposed to use permanent backingstrips, the intended locations and welding procedures are tobe submitted for consideration.

2.4.5 Temporary backing strips may be used providedthey are in accordance with approved welding proceduresand are subsequently removed on completion of welding.




Carbon equivalentCeq

Ceq equal to or lessthan 0,41%

Ceq above 0,41 butnot exceeding

0,45%

Ceq greater than0,45%

Pre-heat

Not required

Not required, see Notes 1 and 2

Required

Hydrogen controlledconsumables

Not required, see Note 3

Required

Required

NOTES1. Preheat may need to be applied in order to meet the maxi-

mum hardness values specified in Ch 12,2.12.6.2. Under conditions of high restraint or low ambient temperature

preheat may need to be applied.3. Hydrogen controlled consumables may need to be

considered for welding of (a) Thicker materials (i.e., > 35 mm).(b) Higher strength materials.(c) Welds subject to high restraint.

Table 13.2.1 Preheat and consumable requirementsfor welding of carbon and carbonmanganese steels up to strengthgrade H40

Consumable approval grade Base material alloy grade

RA or WA 5754RB or WB 5086, 5754RC or WC 5083, 5086, 5754RD or WD 6005A, 6061, 6082

Table 13.2.2 Welding of aluminium alloys –Consumable requirements

Consumable Suitable for welding material alloyapproval grade grades

Austenitic stainless steels

321 321347 347 and 321

Austenitic stainless steel – Low carbon

304L (see Note 3) 304L304LN (see Note 3) 304LN and 304L316L 316L and 304L316LN 316LN, 316L, 304LN and 304L317L 317L, 316LN, 316L, 304LN and 304L317LN 317LN, 317L, 316LN, 316L, 304LN and

304L

Super austenitic stainless steels, see Note 2

S31254 S31254 and N08904N08904 N08904

Duplex stainless steels, see Note 1

S31260 S31260 and S31803S31803 S31803S32550 S32550 S32750 S32750 and S32550S32760 S32760, S32550, S31260 and S31803

Stainless steels welded to carbon steels

SS/CMn Carbon steel to all steels in Sections 1, 2 and 3

Duplex/CMn Carbon steel to all duplex stainless steel in Section 4

NOTES1. The use of a different welding consumable grade from that of

the base material may require demonstration of acceptablecorrosion properties.

2. May be used for welding low carbon austenitic grades providedmeasures are taken to prevent solidification cracking fromoccurring.

3. These are LR Grades and do not correspond to any Nationalor International Standards/Grades.

Table 13.2.3 Welding of austenitic stainless andduplex stainless steels – Consumablerequirements

2.7 Closing plates

2.7.1 For the connection of plating to internal webs,where access for welding is not practicable, the closing plating is to be attached by continuous full penetration weldsor by slot fillet welds to face plates fitted to the webs. Slotsare to have a minimum length of 90 mm and a minimum widthof twice the plating thickness, with well rounded ends. Slotscut in plating are to be smooth and clean and are to bespaced not more than 230 mm apart, centre to centre. Slotsare not to be filled with welding.

2.7.2 For the attachment of rudder shell plating to theinternal stiffening of the rudder, slots are to have a minimumlength of 75 mm and, in general, a minimum width of twicethe side plating thickness. The ends of the slots are to berounded and the space between them is not to exceed 150 mm.

2.8 Stud welding

2.8.1 Where permanent or temporary studs are to beattached by welding to main structural parts in areas subjectto high stress, the proposed location of the studs and thewelding procedures adopted are to be approved.

2.4.6 The outer surfaces of completed welds are to blendsmoothly with the base materials and provide a smooth transition and gradual change of section.

2.4.7 Weld joints in parts of oil engine structures that arestressed by the main gas or inertia loads are to be designedas continuous full penetration welds. They are to be arrangedso that welds do not intersect, and that welding can beeffected without difficulty.

2.4.8 When modifications or repairs have been madewhich result in openings having to be closed by weldedinserts, particular care is to be given to the fit of the insert andthe welding sequence. The welding is also to be subject tonon-destructive examination.

2.4.9 Where welding of aluminium alloy is employed, thefollowing additional requirements are to be complied with sofar as they are applicable:(a) Welding is to be performed by fusion welding using inert

gas or tungsten inert gas process or by the friction stirwelding process. Where it is proposed to use otherwelding processes, details are to be submitted forapproval.

(b) The weld joint surfaces should be scratch brushed,preferably immediately before welding, in order toremove oxide or adhering films of dirt, filings, etc.

2.5 Butt welds

2.5.1 Where the ship hull is constructed of plates ofdifferent thicknesses, the thicker plates are to be chamfered inaccordance with the approved plans. In all cases the chamferis not to exceed a slope of 1 in 3 so that the plates are ofequal thickness at the weld seam. Alternatively, if so desired,the width of the weld may be included as part of the smoothtaper to the thicker plate provided the difference in thicknessis not greater than 3 mm.

2.5.2 Where stiffening members are attached by continuous fillet welds and cross completely finished butt orseam welds, these are to be made flush in way of the filletweld. Similarly for butt welds in webs of stiffening members,the butt weld is to be complete and generally made flush withthe stiffening member before the fillet weld is made. Wherethese conditions cannot be complied with, a scallop is to bearranged in the web of the stiffening member, see Fig. 13.2.1.Scallops are to be of such a size and in such a position that asatisfactory weld can be made.

2.6 Lap connections

2.6.1 Overlaps are generally not to be used to connectplates which may be subjected to high tensile or compressiveloading and alternative arrangements are to be considered.However, where plate overlaps are adopted, the width of theoverlap is not to exceed four times, nor be less than threetimes the thickness of the thinner plate and the joints are to bepositioned to allow adequate access for completion of soundwelds. The faying surfaces of lap joints are to be in closecontact and both edges of the overlap are to have continuous fillet welds.



LLOYD’S REGISTER8

150 mmmax.

(a) Staggered intermittent

s

150 mmmax.

(b) Chain intermittent

sd

d

150 mmmax.

sd

Depth of scallop not greaterthan 0,25dw or 75 mm, whichever is the lesser

Welding to be carriedround ends of all lugs

Radius not lessthan 25 mm dw

(c) Scalloped construction

NOTE s to be not less than 75 mm, in all cases

Fig. 13.2.1 Weld types

2.10.3 Where required, heat treatment is to be performedin accordance with the requirements specified in 4.6 for pressure vessel construction.

2.10.4 Special consideration may be given to omit therequired post-weld heat treatment. Evaluation is to be basedon critical engineering assessment involving fracture mechanics testing and proposals are to be submitted whichinclude full details of the application, materials, welding procedures, inspection procedures, design stresses, fatigueloads and cycles. Evidence will be required to demonstratethat the inspection techniques and procedures to beemployed are able to detect flaws down to the sizes determined from the fracture mechanics (and or fatigue)calculations. Alternative procedures for omission of post-weldheat treatment will be subject to special consideration.

2.11 Tolerances

2.11.1 Tolerances after welding are to be in accordancewith the relevant Part of the Rules.

2.11.2 Distortion which has resulted from welding may becorrected by spot heating in accordance with 1.14.

2.12 Non-destructive examination of welds

2.12.1 All finished welds are to be sound and free fromcracks and substantially free from lack of fusion, incompletepenetration, porosity and slag. The surfaces of welds are tobe reasonably smooth and substantially free from undercutand overlap. Care is to be taken to ensure that the specifieddimensions of welds have been achieved and that bothexcessive reinforcement and under-fill of welds is avoided.

2.12.2 Welds forming part of the hull and superstructuremay be coated with a thin layer of protective primer prior toinspection provided it does not interfere with inspection and isremoved, if required by the Surveyor, for closer interpretationof possible defective areas.

2.12.3 All welds are to be visually inspected by personneldesignated by the builder. Visual inspection of all welds maybe supplemented by other non-destructive examination techniques in cases of unclear interpretation, as considerednecessary. The acceptance criteria for visual testing are givenin Table 13.2.4.

2.12.4 In addition to visual inspection, welded joints are tobe examined using any one or a combination of ultrasonic,radiographic, magnetic particle, eddy current, dye penetrantor other acceptable methods appropriate to the configurationof the weld.

2.9 Fillet welds

2.9.1 T-connections are generally to be made by filletwelds on both sides of the abutting plate, the dimensions andspacing of which are shown in Fig. 13.2.1. Where the connec-tion is highly stressed, deep penetration or full penetrationwelding may be required. Where full penetration welding isrequired, the abutting plate may be required to be bevelled.

2.9.2 Where an approved deep penetration procedure isused, the fillet leg length calculated may be reduced by 15 percent provided that the manufacturer is able to meet the following requirements:(a) Use of a welding consumable approved for deep

penetration welding in accordance with Chapter 11 foreither the ‘p’ or ‘T’ techniques.

(b) Demonstrations by way of production weld testing thatthe minimum required penetration depths (i.e., throatthicknesses) are maintained. This is to be documentedon a monthly basis by the manufacturer and be availableto the Surveyor.

2.9.3 The calculated fillet leg length may be reduced by20 per cent, provided that in addition to the requirements of2.9.2(a) and (b), the manufacturer is able to consistently meetthe following additional requirements:(a) The documentation required in 2.9.2(b) is to be

completed and made available to the Surveyor uponrequest on a weekly basis.

(b) Suitable process selection confirmed by satisfactorywelding procedure tests covering both minimum andmaximum root gaps.

2.9.4 Where intermittent welding is used, the welding isto be made continuous in way of brackets, lugs and scallopsand at orthogonal connections with other members.


2.10.1 Post-weld stress relief heat treatment is applied toimprove the fatigue performance or to improve resistance tobrittle fracture and is generally required for carbon andcarbon-manganese and low alloy steels under any of thefollowing conditions:(a) Where the material thickness exceeds 65 mm.(b) For complicated weld joints where there are high stress

concentrations.(c) Where fatigue loads are considered high.

2.10.2 Post-weld heat treatment is to be applied to thefollowing types of welded construction:(a) Welding of steel castings where the thickness of the

casting at the weld exceeds 30 mm, except where castings are directly welded to the hull structure.

(b) Oil engine bedplates except engine types where thebedplate as a whole is not subjected to direct loadingfrom the cylinder pressure. For these types, only thetransverse girder assemblies need to be stress relieved.

(c) Welding of gear wheels.(d) Welding of gear cases associated with main or auxiliary

engines, see Part 5 of the Rules for Ships.




2.12.11 Special attention is to be given to the examinationof plating in way of lifting eye plate positions to ensure freedom from cracks. This examination is not restricted to thepositions where eye plates have been removed, but includesthe positions where lifting eye plates are permanent fixtures.

2.12.12 Checkpoints for volumetric examination are to beselected so that a representative sample of welding is examined.

2.12.13 Typical locations for volumetric examination andnumber of checkpoints to be taken are given in the relevantSections of the Rules. A list of the proposed items to beexamined is to be submitted for approval.

2.12.14 For the hull structure of refrigerated spaces, and ofships designed to operate in low air temperatures, the extentof non-destructive examination will be specially considered.For non-destructive examination of gas ships see the Rulesfor the carriage for Liquefied Gases.

2.12.15 For all ship types, the builder is to carry out randomnon-destructive examination at the request of the Surveyor.

2.12.16 Results of non-destructive examinations madeduring construction are to be recorded and evaluated by thebuilder on a continual basis in order that the quality of weldingcan be monitored. These records are to be available to theSurveyor.

2.12.17 The extent of applied non-destructive examinationsis to be increased when warranted by the analysis of previousresults.

2.12.5 The method to be used for the volumetric examinations of welds is the responsibility of the builder.Radiography is generally preferred for the examination of buttwelds of 8 mm thickness or less. Ultrasonic testing is acceptable for welds of 8 mm thickness or greater and is tobe used for the examination of full penetration tee butt orcruciform welds or joints of similar configuration. Advancedultrasonic techniques, such as Phased Array UltrasonicTesting (PAUT), may be used as a volumetric testing methodin lieu of radiography or manual ultrasonic testing. If thesemethods are used, the thickness limitations for manual ultrasonic testing apply.

2.12.6 The acceptance criteria for radiographic testing aregiven in Table 13.2.5, and those for ultrasonic testing in Table 13.2.6.

2.12.7 Checkpoints examined at the pre-assembly stageare to include ultrasonic testing on examples of the stop/startpoints of automatic welding and magnetic particle inspectionof weld ends.

2.12.8 Checkpoints examined at the assembly stage aregenerally to be selected from those welds intended to beexamined as part of the agreed quality control programme tobe applied by the builder. The locations and number of check-points are to be approved by the Surveyor.

2.12.9 Where components of the structure are subcon-tracted for fabrication, the same inspection regime is to beapplied as if the item had been constructed within the maincontractor’s works. In these cases, particular attention is tobe given to highly loaded fabrications (such as stabiliser finboxes) forming an integral part of the hull envelope.

2.12.10 Particular attention is to be paid to highly stresseditems. Magnetic particle inspection is to be used at ends offillet welds, T-joints, joints or crossings in main structuralmembers and at stern frame connections.




Surface discontinuity

Crack

Lack of fusion

Incomplete root penetration in butt joints welded from one side

Surface pore

Undercut in butt welds

Undercut in fillet welds

Classification according to ISO 6520-1

100

401

4021

2017

501

501

Acceptance criteria for visual testing

Not accepted

Not accepted

Not accepted

Single pore diameter d ≤ 0,25t, for butt welds, withmaximum diameter 3 mm, see Note 1

d ≤ 0,25a, for fillet welds, with maximum diameter 3 mm, see Note 1

2,5d as minimum distance to adjacent pore

Depth ≤ 0,5 mm, whatever the lengthDepth ≤ 0,8 mm, with a maximum continuous length

of 90 mm, see Note 2

Depth ≤ 0,8 mm, whatever the length

NOTES1. t is the plate thickness of the thinnest plate, and a is the throat of the fillet weld.2. Adjacent undercuts separated by a distance shorter than the shortest undercut are to be regarded as a single continuous undercut.

Table 13.2.4 Acceptance criteria for visual testing, magnetic particle and liquid penetrant testing

2.13.2 During the assembly of large components, rootgaps in excess of those specified in the approved weldingprocedure may be rectified by welding.

2.13 Weld repairs

2.13.1 The full extent of any weld defect is to be ascer-tained by applying additional non-destructive examinationwhere required. Unacceptable defects are to be completelyremoved and, where necessary, re-welded and re-examinedin accordance with the requirements of 1.15.




Discontinuity Classification according to ISO 6520-1 Acceptance criteria for radiographic testing, see Note 1

Crack 100 Not accepted

Lack of fusion 401 Continuous maximum length t/2 or 25 mm, whichever is the less, see Note 2

Intermittent cumulative length maximum t or 50 mm, whichever is less, see Note 3

Lack of root fusion 4013 Not accepted in butt joints welded from one side

Incomplete root penetration 4021 Not accepted in butt joints welded from one side

Continuous maximum length t/2 or 25 mm, whichever is lesser, see Note 2

Intermittent cumulative maximum length t or 50 mm, whichever is less, see Note 3

Slag inclusion 301 Continuous maximum length t or 50 mm, whichever is less, see Note 2

Intermittent cumulative length maximum 2t or 100 mm, whichever is less, see Notes 3 and 4

Gas pore 2011 Maximum dimension for a single pore:d ≤ 0,2t, max. 4,0 mmsee Note 5

Uniformly distributed porosity 2012 Maximum dimension of the area of imperfections:For single run welds: ≤ 1,5%For multi-run welds: ≤ 3%See Notes 6 and 7

Clustered (localised) porosity 2013 Maximum dimension of the summation of the projected area of the imperfection: ≤ 8%

See Notes 6 and 7

Elongated cavity 2015 h ≤ 0,3t, max. 3,0 mml ≤ t, max. 50 mmSee Notes 8 and 9

Wormholes 2016 h ≤ 0,3t, max. 3,0 mml ≤ t, max. 50 mmSee Notes 8 and 9

Metallic inclusions other than copper 304 h ≤ 0,3t, max. 3,0 mmSee Note 8

Copper inclusions 3042 Not permitted

NOTES1. t is the thickness of the thinnest plate.2. Two adjacent individual discontinuities of length ld1 and ld2 situated on a line and where the distance ld between them is shorter than

the shortest discontinuity are to be regarded as a continuous discontinuity of length ld1 + ld + ld2 .3. Sum of the length of individual continuous discontinuities.4. Parallel inclusions not separated by more than 3 times the width of the largest inclusion are to be regarded as one continuous

discontinuity.5. d is the diameter of the gas pore.6. The limits for the maximum single gas pore within this group still apply.7. Further reference to porosity limits may be obtained in ISO 5817:2007.8. h is the width of the imperfection.9. l is the length of the imperfection.

Table 13.2.5 Acceptance criteria for radiographic testing

(c) Welding procedure qualification tests are carried outwithout preheat.

(d) The thickness of steel plate used in the welding procedurequalification test is the minimum hull plate thickness tobe used during fabrication.

(e) The maximum measured hardness on the completedwelding procedure qualification assembly is less than orequal to 350 HV10. Following fabrication welding, 10 percent of welds are to be hardness tested in way of heat-affected zones at weld starts to confirm compliance withthe 350 HV10 limit.

(f) The heat input used in the welding qualification test isthe minimum permitted heat input during fabrication.

(g) Only low hydrogen welding consumables (H5) are used.(h) In addition to normal non-destructive testing for welds,

10 per cent of the welds are additionally subject tomagnetic particle inspection 48 hours after welding iscomplete.

(j) The welding procedure qualification tests for the repairof welds carried out afloat with water backing are to becarried out on test pieces that have previously beenwelded afloat and also meet the requirements above.

2.14.2 For new construction, conversion or permanentrepairs, wet underwater welding is not permitted.

■ Section 3Specific requirements for fabricated steel sections

3.1 Scope

3.1.1 Fabricated steel sections are items used in place ofrolled sections and as such will not be regarded as sub-assemblies. Products regarded as sub-assemblies are subjectto requirements of welded construction specified in Section 2.

3.1.2 The requirements for structural steel sections arebased on these being manufactured from flat products byautomatic welding and intended for use in the construction ofships and other marine structures.

3.1.3 Fabricated steel sections are to be manufactured inaccordance with the requirements of this Section and thegeneral requirements of Section 1.

2.13.3 Rectification of wide root gaps in butt welds, up toa maximum gap of 16 mm, may be performed provided thatthe length of these areas is small in relation to the whole weldlength. Repairs may be executed by applying weld butteringlayers to one edge of the weld joint, followed by machining orgrinding to return the root opening to the required dimensions.The weld buttering and filling of the joint are to be in accor-dance with welding procedures qualified in accordance withChapter 12.

2.13.4 For sub-assemblies, rectification of wide root gapsmay be performed using a backing strip, provided that it isremoved on completion of the welding.

2.13.5 Rectification of wide root gaps in fillet welds may becarried out as follows:(a) where the root gap, g, is in excess of 3 mm, but not

greater than 5 mm, the fillet leg length, z, may beincreased by g – 2,0 mm;

(b) where the root gap is in excess of 5 mm, the joint detailmay be changed into a full penetration weld.

2.13.6 Where repair welds are made using small weldbeads, suitable precautions (including preheat) are to be takento avoid high hardness and possible cold cracking.

2.14 Welding afloat with water backing

2.14.1 Welding afloat with water backing is not recom-mended due to the additional precautions required duringsurvey and therefore, is generally not permitted. Howeverconsideration may be given to welding afloat with water backing after specific LR approval has been obtained by theyard or fabricator prior to such welding being carried out.Such approval will only be given once all of the followingconditions are satisfied:(a) The welding procedure qualification tests are carried out

on steel plates with water backing and the water is maintained at the flow rate and minimum water temper-ature anticipated during fabrication.

(b) The carbon equivalent of the steel plates used in thewelding procedure qualification tests are to be greaterthan 0,41 per cent based on the IIW formula. Where itcan be shown that all hull steel plates and new sectionswill have a carbon equivalent value below this figure,steel plates with the maximum carbon equivalent valuemay be used for the welding procedure qualificationtests.




Echo height Acceptance criteria for ultrasonic testing, see Note

Greater than 100% of DAC curve Maximum length t/2 or 25 mm, whichever is less

Greater than 50% of DAC curve, but less than 100% of DAC curve Maximum length t or 50 mm, whichever is less

Indications evaluated to be cracks are unacceptable regardless of echo height;Indications evaluated to be lack of penetration or lack of root fusion in joints welded from one side are unacceptable regardless of echoheight.

NOTETwo adjacent individual discontinuities of length L1 and L2 situated on a line and where the distance L between them is shorter than the shortest discontinuity are to be regarded as a continuous discontinuity of length L1 + L + L2.

Table 13.2.6 Acceptance criteria for ultrasonic testing

3.4.3 Welding procedures are to be established for thewelding of all joints including weld repairs and are to beapproved in accordance with Chapter 12. Welders are to beapproved in accordance with Chapter 12, and qualificationrecords are to be available to the Surveyor.

3.4.4 The welding consumables used are to be approvedin accordance with Chapter 11 and are to be suitable for thetype of joint and grade of steel as described in 2.2. For joiningsteel of different tensile strengths, the consumables are to besuitable for the tensile strength of the component consideredin the determination of weld size.

3.4.5 The application of pre-heat and the use of lowhydrogen welding consumables are to be in accordance withthe requirements of 2.2.

3.4.6 Welding is to be double continuous fillet welding orfull penetration welding as specified in the approved plans.

3.4.7 Where deep penetration welding is used, therequirements of 2.9.2 are to be complied with.


3.5.1 Surface inspection and verification of dimensionsare the responsibility of the manufacturer and are to be carriedout on all materials prior to despatch. Acceptance by theSurveyor of material later found to be defective does notabsolve the manufacturer from this responsibility.

3.5.2 The Surveyor will carry out checks to ensure thatthe weld size and profile are in accordance with the manufacturing specification and the manufacturer’s QualityControl Procedures.

3.5.3 The manufacturer is to examine the welds bymagnetic particle or dye penetrant methods. The lengthexamined is to be 200 mm at each end, for each length cut fordelivery.

3.5.4 If cracks are revealed, these are to be reported tothe Surveyor and the whole of the length is to be examinedby magnetic particle or dye penetrant methods. Correctiveaction in respect of the manufacturing process, and repairsare to be as indicated in the manufacturers’ Quality ControlManual.

3.5.5 The weld defect is not to exceed the acceptancelevels given in Table 13.2.4.

3.6 Routine weld tests

3.6.1 One production batch test is required for every 500 m of fabricated section manufactured, or fraction thereof.From each batch test, two samples are to be removed, onefrom near the beginning of the production run and one fromnear the end. From each of these test samples one macrospecimen and one fracture test specimen are to be taken.

3.1.4 In all cases, sections are to be manufactured atworks, which have been assessed and approved in accor-dance with Materials and Qualification Procedures for Ships,Book J, MQPS Procedure 12-1.


3.2.1 Products are to conform dimensionally to the provisions of an acceptable National or International Standard.

3.2.2 The minimum throat thickness of fillet welds is to bedetermined from:

Throat thickness = 0,34t but not to be taken as lessthan 3 mm

wheret = plate thickness of the thinner member to be joined

(generally the web).

3.2.3 Where a welding procedure using deep penetrationwelding is used (see Chapter 11, ‘p’ and ‘T’ welding techniques)the minimum leg length required will be specially consideredprovided the requirements of 2.9.2 are complied with.

3.2.4 Unless agreed otherwise, the leg length of the weldis to be not less than 1,4 times the specified throat thickness.

3.3 Identification of products

3.3.1 Every finished item is to be clearly marked by themanufacturer in at least one place with the following particulars:(a) The manufacturer’s name or trade mark.(b) Identification mark for the grade of steel.(c) Identification number and/or initials which will enable the

full history of the item to be traced.(d) Where required by the purchaser, the order number or

other identification mark.(e) The letters ‘LR’.(f) The Surveyor’s personal stamp.The above particulars, but excluding the manufacturer’s nameor trade mark where this is embossed on finished products,are to be encircled with paint or otherwise marked so as tobe easily recognisable.

3.3.2 In the event of any material bearing LR’s brand failing to comply with the test requirements, the brand is tobe removed or unmistakably defaced, see also Ch 1,4.7.

3.4 Manufacture and workmanship

3.4.1 For cut edges that are to remain unwelded, it is tobe demonstrated that the plate preparation procedures usedare able to achieve edges that are free from cracks or otherdeleterious imperfections.

3.4.2 Where assembly jigs and devices are used to bringthe web into contact with the flanges and hold these in placeduring welding, means are to be provided to ensure that thedegree of contact is maintained until welding is complete.




4.1.2 The allocation of pressure vessel Class is deter-mined from the design criteria in Pt 5, Ch 10 and 11 of theRules for Ships. Prior to commencing construction, the designof the vessel is to be approved. Construction requirements forturbine rotors and cylinders are to be in accordance withClass 2/1, unless a higher Class is specified in the approvedplans.

4.1.3 Pressure vessels will be accepted only if manufac-tured by firms equipped and competent to undertake thequality of welding work required for the Class of vesselproposed. The manufacturer’s works are to be approved inaccordance with the requirements specified in Materials andQualification Procedures for Ships, Book A, Procedure MQPS0-4.

4.1.4 The term ‘fusion weld’, for the purpose of theserequirements, is applicable to welded joints made by manual,semi-automatic, or automatic electric arc welding processes.Special consideration will be given to the proposed use ofother fusion welding processes.

4.2 Cutting and forming of shells and heads

4.2.1 Cut or chipped surfaces which will not be subse-quently covered by weld metal are to be ground smooth.

4.2.2 Shell plates and heads are to be formed to thecorrect contour up to the extreme edge of the plate.

4.2.3 Vessels manufactured from carbon or carbonmanganese steel plates (see Table 3.4.1 in Chapter 3, grades360AR to 510FG), which have been hot formed or locallyheated for forming, are to be re-heat treated in accordancewith the original supplied condition on completion of this operation. Vessels formed from plates supplied in the as-rolled condition are to be heat treated in accordance withthe material manufacturer’s recommendations.

4.2.4 Subsequent heat treatment will not be requiredwhere steels are supplied in the as-rolled, normalised ornormalised and controlled rolled condition, or hot forming iscarried out entirely at a temperature within the normalisingrange.

4.2.5 For alloy steel vessels where hot forming isemployed (see Table 3.4.1 in Chapter 3, 13Cr Mo 45, etc.),the plates are to be heat treated on completion in accordancewith the material manufacturer’s recommendations.

4.2.6 Where plates are cold formed, subsequent heattreatment is to be performed where the internal radius is lessthan 10 times the plate thickness. For carbon and carbon-manganese steels this heat treatment may be a stress reliefheat treatment.

4.2.7 In all cases where hot forming is employed, and forcold forming to a radius less than 10 times the thickness, themanufacturer is required to demonstrate that the formingprocess and subsequent heat treatments result in acceptableproperties.

3.6.2 The macro specimens are to be prepared andetched to demonstrate freedom from unacceptable defectsand that the weld penetration is in accordance with the manufacturing specification. The fracture specimens are to bebroken, one for each side of the fillet weld, and the fracturedsurfaces examined for compliance with the requirements ofTable 13.2.5.

3.6.3 Where the welding procedure used has employedthe deep penetration technique, the amount of root penetra-tion is to be measured on the macro specimen and is not tobe less than that demonstrated during welding procedureapproval testing.

3.6.4 For the purposes of this Section, a batch is toconsist of products of only one size and grade of material.

3.7 Certification and records

3.7.1 Each test certificate is to include the followingparticulars:(a) Purchaser’s name and order number.(b) Where known, the contract number for which the

material is intended.(c) Address to which material is despatched.(d) Description and dimensions of the product.(e) Specification or grade of the steel.(f) Identification number and/or initials.(g) Cast number and chemical composition of ladle samples

of constituent plates.(h) Mechanical test results of constituent plates.(j) Condition of supply when other than as-rolled.(k) Make and brand of welding consumables.

3.7.2 Test certificates or shipping statements may besigned by the Surveyor, provided the documentation require-ments of 1.17 are satisfied. The following form of declarationwill be accepted if stamped or printed on each test certificateor shipping statement with the name of the works and signedby an authorised representative of the manufacturer:

‘We hereby certify that the material has been madeby an approved procedure in accordance with the Lloyd’sRegister’s Rules for Materials’.

3.7.3 The manufacturer is to maintain records by whichsources of material can be identified together with the resultsof all inspections and tests.

■ Section 4Specific requirements for fusionwelded pressure vessels

4.1 Scope

4.1.1 The requirements of this Section apply to fusionwelded pressure vessels and process equipment, heating andsteam raising boilers, and steam or gas turbine rotors andcylinders and are in addition to those requirements referred toin Section 1.




4.3 Fitting of shell plates and attachments

4.3.1 The location of welded joints is to be such as toavoid intersecting butt welds in the vessel shell plates. Theattachment of nozzles and openings in the vessels are to bearranged to avoid main shell weld seams.

4.3.2 The surfaces of the plates at the longitudinal orcircumferential seams are not to be out of alignment with eachother, at any point, by more than 10 per cent of the platethickness. In no case is the misalignment to exceed 3 mm forlongitudinal seams, or 4 mm for circumferential seams.

4.3.3 Where a vessel is constructed of plates of differentthicknesses (tube plate and wrapper plate), the plates are tobe so arranged that their centrelines form a continuous circle.

4.3.4 For longitudinal seams, the thicker plate is to beequally chamfered inside and outside by machining over acircumferential distance not less than twice the difference inthickness, so that the plates are of equal thickness at thelongitudinal weld seam. For the circumferential seam, thethickest plate is to be similarly prepared over the samedistance longitudinally.

4.3.5 For the circumferential seam, where the differencein the thickness is the same throughout the circumference,the thicker plate is to be reduced in thickness by machining toa taper for a distance not less than four times the offset, sothat the two plates are of equal thickness at the weld joint. Aparallel portion may be provided between the end of the taperand the weld edge preparation; alternatively, if so desired, thewidth of the weld may be included as part of the smooth taperto the thicker plate.

4.3.6 All attachments (lugs, brackets, reinforcing plates,etc.) are to conform to the shape of the surface to which theyare attached.

4.4 Welding

4.4.1 Welding procedures are to be established for allwelds joining pressure containing parts and for welds madedirectly onto pressure containing parts. Welding proceduresare to be based on qualification tests performed in accor-dance with Chapter 12.

4.4.2 In all cases where tack welds, in the root of the weldseam, are used to retain plates or parts in position prior to welding, they are to be removed in the process of welding theseam.

4.4.3 Steel backing strips may be used for the circumfer-ential seams of Class 2/1, Class 2/2 and Class 3 pressurevessels and are to be the same nominal composition as theplates to be welded.

4.4.4 Fillet welds are to be made to ensure proper fusionand penetration at the root of the fillet. At least two layers ofweld metal are to be deposited at each weld affixing branchpipes, flanges and seatings.




4.4.5 The outer surface of completed welds is to be atleast flush with the surface of the plates joined, and any weldreinforcement is to provide a smooth transition and gradualchange of section with the plate surface.

4.4.6 Where attachment of lugs, brackets, branches,manhole frames, reinforcement plates and other members areto be made to the main pressure shell by welding, this is tobe to the same standard as required for the main vessel shellconstruction.

4.4.7 The main weld seams and all welded attachmentsmade to pressure containing parts are to be completed priorto post-weld heat treatment.

4.4.8 The finish of welds attaching pressure parts andnon-pressure parts to the main pressure shell is to be suchas to allow satisfactory examination of the welds. In the caseof Class 1 and Class 2/1 pressure vessels, these welds are tobe ground smooth, if necessary, to provide a suitable finishfor examination.

4.5 General requirements for routine weld production tests

4.5.1 Routine weld production tests are specified as ameans of monitoring the quality of the welded joints and arerequired for pressure vessel Classes 1, 2/1 and 2/2.

4.5.2 Routine production test plates are required duringthe manufacture of vessels and as part of the initial approvaltest programme for Class 1 vessel manufacturers, refer toMQPS 0-4.

4.5.3 Routine production weld tests are not required forClass 3 pressure vessels unless there are doubts about theweld quality where check tests may be requested by theSurveyor.

4.5.4 Routine production test plates are not required forcircumferential seams of cylindrical pressure vessels.Spherical vessels are to have one test plate prepared havinga welded joint which is a simulation of the circumferentialseams.

4.5.5 Routine production weld tests may be requested bythe Surveyor where there is reason to doubt the quality ofworkmanship.

4.6 Production test plate assembly requirements

4.6.1 Two test plates and one complete test assembly, ofsufficient dimensions to provide all the required mechanicaltest specimens is to be prepared for each vessel and is to bewelded as a continuation and simulation of the longitudinalweld joint.

4.6.2 For Class 2/2 vessels, where a large number aremade concurrently at the same works using the same weldingprocedure and the plate thicknesses do not vary by more than5 mm, one test may be performed for each 37 m of longitudinalplus circumferential weld seam. In these cases the thicknessof the test plate is to be equal to the thickest shell plate usedin the construction.

4.6.3 Where the vessel size or design results in a smallnumber of longitudinal weld seams, one test assembly maybe prepared for testing provided that the welding details arethe same for each seam.

4.6.4 Test plate materials are to be the same grade,thickness and supply condition and from the same cast asthat of the vessel shell. The test assembly is to be welded atthe same time as the vessel weld to which it relates and is tobe supported so that distortion during welding is minimised.

4.6.5 As far as practicable, welding is to be performed bydifferent welders where there is a requirement for severalroutine tests to be welded.

4.6.6 The test assembly may be detached from thevessel weld only after the Surveyor has performed a visualexamination and has added his mark or stamp. Straighteningof test welds prior to mechanical testing is not permitted.

4.6.7 Where the pressure vessel is required to besubjected to post-weld heat treatment, the test weld is to beheat treated, after welding, in accordance with the samerequirements. This may be performed separately from thevessel.

4.7 Inspection and testing

4.7.1 The test weld is to be subjected to the same type ofnon-destructive examination and acceptance criteria as specified for the weld seam to which the test relates. Non-destructive examination is to be performed prior to removingspecimens for mechanical testing, but after any post-weldheat treatment.

4.7.2 The test weld is to be sectioned to remove thenumber and type of test specimens for mechanical testing asgiven in 4.8.

4.8 Mechanical requirements

4.8.1 The routine production test assembly is to bemachined to provide the following test specimens:(a) Tensile.(b) Bend.(c) Hardness.(d) Impact (see Table 13.4.1).(e) Macrograph and hardness survey of full weld section.

4.8.2 One set of specimens for mechanical testing are tobe removed, as shown in Figs. 13.4.1 or 13.4.2 as appropriatefor the Class of approval. Impact tests are to be removed andtested where required by Table 13.4.1.

4.8.3 Longitudinal tensile test for weld metal. An all-weld metal longitudinal tensile test is required. For thicknesses in excess of 20 mm, where more than one welding process or type of consumable has been used tocomplete the joint, additional longitudinal tests are requiredfrom the respective area of the weld. This does not apply tothe welding process or consumables used solely to depositthe root weld. Specimens are to be tested in accordance withthe following requirements:(a) The diameter and gauge length of the test specimen is to

be in accordance with Ch 11,2.1.1.(b) For carbon and carbon-manganese steels the tensile

strength of the weld metal is to be not less than the minimum specified for the plate material and not morethan 145 N/mm2 above this value. The percentage elongation, A, is to be not less than that given by:

A = (980-R)/21,6 but not less than 80 per cent of theminimum elongation specified for the plate

whereR is the tensile strength, in N/mm2, obtained from the allweld metal tensile tests.

(c) For other materials the tensile strength and percentageelongation is not to be less than that specified for thebase materials welded.

4.8.4 Transverse tensile test for joint. Transversetensile test specimens are to be removed and tested in accor-dance with the following requirements:(a) One reduced section tensile test specimen is to be cut

transversely to the weld to the dimensions shown in Ch 11,2.1.1 and the weld reinforcement is to beremoved.




Pressure vessel ClassMinimum design Plate material thickness

Impact test temperaturetemperature t

Class 1 –10°C or above All 5°C below the minimum design temperature or 20°C,see Note whichever is the lower

t ≤ 20 mm 5°C below the minimum design temperature

All Classes Below –10°C 20 mm < t ≤ 40 mm 10°C below the minimum design temperature

Over 40 mm Subject to special consideration

NOTEImpact testing is not required for Classes 2/1, 2/2 and 3.

Table 13.4.1 Impact test requirements

(b) In general, where the plate thickness exceeds 30 mm,or where the capacity of the tensile test machineprevents full thickness tests, each tensile test may bemade up of several reduced section specimens,provided that the whole thickness of the weld issubjected to testing.

(c) The tensile strength obtained is to be not less than theminimum specified tensile strength for the plate material,and the location of the fracture is to be reported.

4.8.5 Transverse bend test. The bend test specimensare to be removed and tested in accordance with the followingrequirements:(a) Two bend test specimens of rectangular section are to

be cut transversely to the weld, one bent with the outersurface of the weld in tension (face bend), and the otherwith the inner surface in tension (root bend).

(b) The specimen dimensions are to be in accordance withChapter 2.

(c) Each specimen is to be mounted on roller supports withthe centre of the weld midway between the supports.The former is to have a diameter specified in Ch 12,2.7.6depending on the material being welded.

(d) After bending through an angle of at least 180° there isto be no crack or defect exceeding 1,5 mm measuredacross the specimen or 3 mm measured along the specimen. Premature failure at the edges of the specimen is not to be cause for rejection, unless this isassociated with a weld defect.




2

2

3

444

1

Approximately 300 mmto suit testing machine


of weldCL

1. Tensile test for joints.2. Bend test specimens.3. Nicked bend test specimen.4. Charpy V-notch impact test specimens (if required by Table 13.4.1).

Fig. 13.4.2Routine weld tests – Test specimens for

Class 2/2 and Class 3

2

2

3

4555

1

Approximately 300 mmto suit testing machine


of weldCL

1. All weld metal tensile test specimen.2. Bend test specimens.3. Tensile test for joints.4. Macro-test specimen.5. Charpy V-notch impact. (For all Class 1 pressure vessels and other Classes of pressure vessels where the minimum design temperature is below –10°C).

Fig. 13.4.1Routine weld test – Test specimens for

Class 1 and Class 2/1

4.8.6 Macro-specimen and hardness survey. A macroexamination specimen is to be removed from the test assembly near the end where welding started. The specimenis to include the complete cross-section of the weld and theheat affected zone. The specimen is to be prepared andexamined in accordance with the following requirements:(a) The cross-section of the specimen is to be ground,

polished and etched to clearly reveal the weld runs, andthe heat affected zones.

(b) The specimen is to show an even weld profile thatblends smoothly with the base material and have satisfactory penetration and fusion, and an absence ofsignificant inclusions or other defects.

(c) Where there is doubt in the condition of the weld asshown by macro-etching, the area concerned is to bemicroscopically examined.

(d) For carbon, carbon manganese and low alloy steels, aVickers hardness survey is to be performed on themacro-specimen using either a 5 kg or 10 kg load.Testing is to include the base material, the weld and theheat affected zone. Hardness scans on the cross-section are to be performed as specified in Fig. 12.2.9in Chapter 12. The maximum recorded hardness is tonot exceed 350 Hv.

4.8.7 Charpy V-notch impact test. Charpy V notchimpact test specimens are to be prepared and tested asrequired by Table 13.4.1 and in accordance with the followingrequirements:(a) The dimensions and tolerances of the specimens are to

be in accordance with Chapter 2.(b) Charpy V-notch impact specimens and are to be

removed with the notch perpendicular to the platesurface.

(c) Specimens are to be removed for testing from the weldcentreline and the heat affected zone (fusion line andfusion line + 2 mm locations) detailed in Fig. 12.2.6 orFig. 12.2.7 in Chapter 12, as appropriate. Heat affectedzone impact tests may be omitted where the minimumdesign temperature is above +20°C.

(d) For thicknesses in excess of 20 mm, where more thanone welding process or type of consumable has beenused to complete the joint, impact tests are requiredfrom the respective areas of the weld. This does notapply to the welding process or consumables usedsolely to deposit the root weld.

(e) The average energy of a set of three specimens is not tobe less than 27 J or the minimum specified for the basematerial, whichever is the higher. The minimum energyfor each individual specimen is to meet the requirementsof Ch 1,4.5.2.

4.8.8 Nick break bend tests. A nick bend or fracturetest specimen is to be a minimum of 100 mm long measuredalong the weld direction and is to be tested in accordancewith and meet the requirements of the following:(a) The specimen is to have a slot cut into each side along

the centreline of the weld and perpendicular to the platesurface.

(b) The specimen is to be bent along the weld centrelineuntil fracture occurs and the fracture faces are to beexamined for defects. The weld is to be sound, with noevidence of cracking or lack of fusion or penetration andbe substantially free from slag inclusions and porosity.

4.9 Failure to meet requirements

4.9.1 Where any test specimen fails to meet the require-ments, additional specimens may be removed and re-testedin accordance with Ch 2,1.4.

4.9.2 Where a routine weld test fails to meet require-ments, the welds to which it relates will be considered as nothaving met the requirements. The reason for the failure is tobe established, and the manufacturer is to take such steps asnecessary to either(a) Remove the affected welds and have them re-welded,

or(b) Demonstrate that the affected production welds have

acceptable properties.


4.10.1 Fusion welded pressure vessels, where indicated inTable 13.4.2, are to be heat treated on completion of thewelding of the seams and of all attachments to the shell andends, and before the hydraulic test is carried out.

4.10.2 Tubes which have been expanded into headers ordrums may be seal welded without further post-weld heattreatment.

4.10.3 Steam and gas turbine cylinders and rotors are tobe subjected to post-weld heat treatment irrespective ofthickness.

4.10.4 Where the weld attaches parts of different thicknesses, the thickness to be used when applying therequirements for post-weld heat treatment is to be either thethinner of the two plates for butt welded connections, or thethickness of the shell for welds to flanges, tubeplates andsimilar connections.

4.10.5 Care is to be exercised to provide drilled holes indouble reinforcing plates and other closed spaces prior toheat treatment.

4.11 Basic requirements for post-weld heat treatment of fusion welded pressure vessels

4.11.1 Recommended soaking temperatures and soakdurations for post-weld heat treatment are given in Table 13.4.3 for different materials. Where other materials areused for pressure vessel construction, full details of theproposed heat treatment are to be submitted for consideration.

4.11.2 Where pressure vessels are of dimensions that thewhole length cannot be accommodated in the furnace at onetime, the pressure vessels may be heated in sections,provided that sufficient overlap is allowed to ensure the heattreatment of the entire length of the longitudinal seam.

4.11.3 Where materials other than those detailed in Table 13.4.3 are used or where it is proposed to adopt specialmethods of heat treatment, full particulars are to be submittedfor consideration. In such cases, it may be necessary to carryout tests to show the effect of the proposed heat treatment.




4.12 Non-Destructive Examination of welds

4.12.1 Non-Destructive Examinations (NDE) of pressurevessel welds are to be carried out in accordance with anationally recognised code or standard.

4.12.2 NDE is not to be applied until an interval of at least48 hours has elapsed since the completion of welding.

4.12.3 NDE Personnel are to be qualified to an appropriatelevel of a nationally recognised certification scheme.

4.12.4 Qualification schemes are to include assessmentsof practical ability for Levels I and II individuals. These examinations are to be made on representative test piecescontaining relevant defects.

4.13 Extent of NDE for Class 1 pressure vessels

4.13.1 All butt welded seams in drums, shells, headersand test plates, together with tubes or nozzles with outsidediameter greater than 170 mm, are subject to 100 per centvolumetric and surface crack detection inspections.

4.13.2 For circumferential butt welds in extruded connec-tions, tubes, headers and other tubular parts with an outsidediameter of 170 mm or less, at least 10 per cent of the totalnumber of welds is to be subjected to volumetric examinationand surface crack detection inspections.

4.13.3 Full penetration tube sheet to shell welds are to besubjected to 10 per cent volumetric examination and 10 percent surface inspection, prior to the installation of the tubes.

4.13.4 In addition to the acceptance limits stated in Tables 13.2.4 to 13.2.6, no cracks, lack of fusion, or lack of penetration is permitted.

4.13.5 When an unacceptable indication is detected, thefull length of the weld is to be subjected to 100 per centexamination by the same method, testing conditions andacceptance criteria.

4.14 Extent of NDE for Class 2/1 pressure vessels

4.14.1 For Class 2/1 pressure vessels, volumetric andsurface crack detection inspections are to be applied atselected regions of each main seam. At least 10 per cent ofeach main seam is to be examined together with the fulllength of each welded test plate. When an unacceptable indication is detected, at least two additional check points inthe seam are to be selected by the surveyor for examinationusing the same inspection method. Where further unaccept-able defects are found either:(a) the whole length of weld represented is to be cut out and

re-welded and re-examined as if it was a new weld withthe test plates being similarly treated, or

(b) the whole length of the weld represented is to be re-examined using the same inspection methods.




Material type Soak temperature (°C) Soak period

Carbon and carbon/manganese grades 580–620° 1 hour per 25 mm of thickness, minimum of 1 hour

1Cr ½Mo 620–660° 1 hour per 25 mm of thickness, minimum of 1 hour

2¼Cr 1Mo 650–690° 1 hour per 25 mm of thickness, minimum of 1 hour

½Cr ½Mo ¼V 670–720° 1 hour per 25 mm of thickness, minimum of 1 hour

NOTEFor materials supplied in the tempered condition, the post-weld heat treatment temperature is to be lower than the material tempering temperature.

Table 13.4.3 Post-weld soak temperatures and times

Plate thickness above which post-weld heat treatment (PWHT) is requiredType of steel

Steam raising plant Other pressure vessels

Carbon and carbon/manganese steels 20 mm 30 mmwithout low temperature impact values

Carbon and carbon/manganese steels 20 mm 40 mmwith low temperature impact values

1Cr ½Mo All thicknesses All thicknesses

2¼Cr 1Mo All thicknesses All thicknesses

½Cr ½Mo ¼V All thicknesses All thicknesses

Other alloy steels Subject to special consideration

Table 13.4.2 Post-weld heat treatment requirements

4.14.2 Butt welds in furnaces, combustion chambers andother pressure parts for fired pressure vessels under externalpressure, are to be subject to spot volumetric examination.The minimum length for each check point is to be 300 mm.

4.14.3 The extent of NDE for turbine cylinders and rotors isto be agreed with the Surveyor.

4.14.4 The requirements of 4.13.3, 4.13.4 and 4.13.5 applyto Class 2/1 pressure vessels.

4.15 NDE Method

4.15.1 Volumetric examinations may be made by radiography. For welds of nominal thickness greater than orequal to 8 mm, the examinations may be by ultrasonic testing.The preferred method for surface crack detection in ferrousmetals is magnetic particle inspection. The preferred methodfor non-magnetic materials is liquid penetrant inspection.

4.16 Evaluation and reports

4.16.1 The manufacturer is to be responsible for thereview, interpretation, evaluation and acceptance of theresults of NDE. Reports stating compliance, or non-compli-ance, with the criteria established in the inspection procedureare to be issued. Reports are to comply, as a minimum, withthe requirements of Ch 1,5.

4.17 Repair to welds

4.17.1 Where non-destructive examinations reveal un-acceptable defects in the welded seams, they are to berepaired in accordance with 1.15 and are to be shown byfurther non-destructive examinations to have been eliminated.

4.17.2 In the case where spot radiography has revealedunacceptable defects, the requirements of 4.14.1 apply.

4.17.3 Where post-weld heat treatment is required inaccordance with 4.10, weld repairs to the vessel or cylindricalshell or parts attaching to the shell are to be subjected to asubsequent heat treatment in accordance with 4.10.

4.17.4 In the event of unsuccessful weld repair of a defect,only one more repair attempt may be made of the samedefect. Any subsequent repairs may require the re-repairexcavation to be enlarged to remove the original repair heataffected zone.

■ Section 5Specific requirements for pressure pipework

5.1 Scope

5.1.1 Fabrication of pipework is to be carried out inaccordance with the requirements of this Section and thegeneral requirements given in Section 1, unless more stringent requirements have been specified.

5.1.2 Piping systems are to be constructed in accor-dance with the approved plans and specifications.

5.1.3 Fabricated pipework will be accepted only if manu-factured by firms that have demonstrated that they have thefacilities and equipment and are competent to undertake thequality of welding required for the Class of pipeworkproposed.

5.2 Manufacture and workmanship

5.2.1 Pipe welding may be performed using manual,semi-automatic or fully automatic electric arc processes. Theuse of oxy-acetylene welding will be limited to Class 3pipework in carbon steel or carbon/manganese material thatis not for carrying flammable fluids and limited to butt joints inpipes not exceeding 100 mm diameter or 9,5 mm thickness.

5.2.2 Welding of pipework, including attachment weldsdirectly to pressure retaining parts is to be performed in accor-dance with approved welding procedures that have beenqualified in accordance with Chapter 12.

5.2.3 Where the work involves a significant number ofbranch connections, tests will be required to demonstrate thatthe type of joint(s) and welding techniques employed arecapable of achieving the required quality.

5.2.4 Where pressure pipework is assembled and buttwelded insitu, the piping is to be arranged well clear of adjacent structures to allow sufficient access for preheating,welding, heat-treatment and non-destructive examination ofthe joints.

5.2.5 Alignment of pipe butt welds is to be in accordancewith Table 13.5.1 unless more stringent requirements havebeen agreed. Where fusible inserts are used, the alignment isto be within 0,5 mm in all cases.

5.2.6 The number of welds is to be kept to a minimum.The minimum separation between welds, measured toe-to-toe, is to be not be less than 75 mm. Where it is not possibleto achieve this, adjacent welds are to be subjected to surfacecrack detection NDE.

5.2.7 Welding consumables and fusible root inserts,where used, are to be suitable for the materials being joined.




5.2.8 Acceptable methods of flange attachment are to beused, see Fig. 12.2.2 in Pt 5, Ch 12 of the Rules for Ships.Where backing rings are used with flange type (a) they are tofit closely to the bore of the pipe and be removed after welding. The rings are to be made of the same material as thepipes. The use of flange types (b) and (c) with alloy steel pipesis limited to pipes up to and including 168,3 mm outsidediameter.

5.2.9 Where socket welded fittings are employed, thediametrical clearance between the outside diameter of thepipe and the base of the fitting is not to exceed 0,8 mm, anda gap of approximately 1,5 mm is to be provided between theend of the pipe and the internal step at the bottom of thesocket.

5.2.10 For welding of carbon, carbon/manganese and lowalloy steels, the preheat to be applied will be dependent onthe material grade, thickness and hydrogen grading of thewelding consumable in accordance with Table 13.5.2, unlesswelding procedure testing indicates that a higher level isrequired.

5.2.11 Welding without filler metal is generally not permittedfor welding of duplex stainless steel materials.

5.2.12 All welds in high pressure, high temperature pipe-lines are to have a smooth surface finish and even contour;and where necessary, made smooth by grinding.

5.2.13 Check tests of the quality of the welding are to becarried out periodically.

5.3 Heat treatment after bending of pipes

5.3.1 After forming or bending of pipes, the heat treat-ments specified in this Section are to be applied unless thepipe material manufacturer specifies or recommends otherrequirements.

5.3.2 Generally, hot forming is to be carried out within thenormalising temperature range. When carried out within thistemperature range, no subsequent heat treatment is requiredfor carbon and carbon/manganese steels. For alloy steels,1Cr 1/2Mo, 21/4Cr 1Mo and 1/2Cr 1/2Mo 1/4V, a subsequenttempering heat treatment in accordance with the tempera-tures and times specified in Table 13.5.3 is required,irrespective of material thickness.

5.3.3 When hot forming is performed outside the normalisingtemperature range, a subsequent heat treatment in accor-dance with Table 13.5.3 is required.

5.3.4 After cold forming to a radius (measured at thecentreline of the pipe) of less than four times the outside diameter, heat treatment in accordance with Table 13.5.3 isrequired.

5.3.5 Heat treatment should be carried out in accordancewith 1.16.




Pipe sizeMaximum permitted

misalignment

D < 150 mm and t ≤ 6 mm 1,0 mm or 25% of t, whichever is the lesser

D < 300 mm and t ≤ 9,5 mm 1,5 mm or 25% of t, whichever is the lesser

D ≥ 300 and t > 9,5 mm 2,0 mm or 25% of t, whichever is the lesser

whereD = pipe internal diametert = pipe wall thickness

Table 13.5.1 Pipe butt weld alignment tolerances

Minimum preheat temperature (°C)Thickness, t See Note 1

Material Grade (mm)see Note 4

Non-low H2Low H2

see Note 2

Carbon and carbon/manganese grades: t ≤ 15 50 10320 and 360 t ≥ 15 100 50

Carbon and carbon/manganese grades: t ≤ 15 75 20410, 460 and 490 t ≥ 15 150 100

1Cr ½Mo t < 13 See Note 3 100t ≥ 13 150

2¼Cr 1Mo t < 13 See Note 3 150t ≥ 13 200

½Cr ½Mo ¼V t < 13 See Note 3 150t ≥ 13 200

NOTES1. Where the ambient temperature is 0°C or below, pre-warming of the weld joint is required in all cases.2. Low hydrogen process or consumables are those that have been tested and have achieved a grading of H15 or better (see Chapter 11).3. Low hydrogen welding process is required for these materials.4. t = the thickness of the thinner member for butt welds, and the thicker member for fillet and branch welds.

Table 13.5.2 Welding preheat levels for pipework

5.3.6 Bending procedures and subsequent heat treat-ment for other alloy steels will be subject to specialconsideration.


5.4.1 Post-weld heat treatment is to be carried out inaccordance with the general requirements specified in 1.16and 4.10.

5.4.2 The thickness limits, the recommended soakingtemperatures and periods, for application of post-weld heattreatment are given in Table 13.5.4.

5.4.3 Where the use of oxy-acetylene welding isproposed, due consideration is to be given to the need fornormalising and tempering after such welding.


5.5.1 Non-destructive examination of pipe welds is to becarried out in accordance with the general requirements of1.11 and the following.

5.5.2 Butt welds in Class 1 pipes with an outside diameter greater or equal to 75 mm are to be subject to 100 per cent volumetric and visual inspections. Considerationis to be given to the extent and method of testing applied tobutt welds in Class 1 pipes with an outside diameter less than75 mm.

5.5.3 Butt welds in Class II pipes are to be subjected to atleast 10 per cent random volumetric inspections when theoutside diameter is greater than 100 mm.

5.5.4 NDE for Class II pipes with a diameter less than 100 mm is to be at the discretion of the Surveyor.

5.5.5 Non-destructive examination procedures, methodsand the evaluation of reports are to be in accordance with4.15 and 4.16.

5.5.6 Fillet welds on flange pipe connections of Class Ipipes are to be examined by surface crack detection methods.

5.6 Repairs to pipe welds

5.6.1 Where non-destructive examinations reveal un-acceptable defects in a weld, the defects are to be removedand repaired in accordance with 1.15. Completed repairs areto be shown by further non-destructive examination to haveeliminated the defects.

5.6.2 For pipes with diameter less than 88 mm andwhere unacceptable defects have been found during non-destructive examination, consideration is to be given tocutting the weld out completely, re-making the weld prepara-tion and re-welding as a new joint (because of the difficulty ofmaking small repairs).




Thickness for which post-weldSoak temperature

Material Gradeheat treatment is required

(°C) Soak periodsee Note 2

Carbon and carbon/manganese grades: Over 30 mm 580–620°C 1 hour per 25 mm of thickness, 320, 360, 410, 460, 490 minimum of 1 hour

1Cr ½Mo Over 8 mm 620–660°C 1 hour per 25 mm of thickness, minimum of 1 hour

2¼Cr 1Mo All 650–690°C 1 hour per 25 mm of thickness, minimum of 1 hour

½Cr ½Mo ¼V All, see Note 1 670–720°C 1 hour per 25 mm of thickness, minimum of 1 hour

NOTES1. Heat treatment may be omitted for thicknesses up to 8 mm and diameters not exceeding 100 mm provided welding procedure tests

have demonstrated acceptable properties in the as welded condition.2. For materials supplied in the tempered condition, the post-weld heat treatment temperature is to be at least 20°C less than the material

tempering temperature.

Table 13.5.4 Post-weld heat treatment requirements for pipework

Type of steel Heat treatment required

Carbon and Normalise at 880 to 940°Ccarbon/manganese:Grades 320, 360, 410, 460 and 490

1Cr ½Mo Normalise at 900 to 940°C, followed bytempering at 640 to 720°C

2¼Cr 1Mo Normalise at 900 to 960°C, followed bytempering at 650 to 780°C

½Cr ½Mo ¼V Normalise at 930 to 980°C, followed bytempering at 670 to 720°C

Other alloy steels Subject to special consideration

Table 13.5.3 Heat treatment after bending of pipes

5.6.3 Where repeated weld repairs have to be made to aweld, only two such attempts are to be permitted, thereafterthe weld is to be cut apart and removed, and re-welded as anew joint.

5.6.4 Where pipework requires post-weld heat treatmentweld, repairs to the pressure retaining parts are to besubjected to a subsequent heat treatment. Similarly, wherewelding is conducted after pressure testing, a further pressure test is to be required unless specific exemption hasbeen agreed.

■ Section 6Repair of existing ships by welding

6.1 Scope

6.1.1 This Section specifies requirements for repairsmade by welding after introduction into service. This Sectionincludes defects to hull structures, machinery, equipment andcomponents. It also includes replacement of structure due todamage or corrosion. These requirements are in addition tothose specified in the preceding Sections of this Chapter.

6.1.2 These requirements apply unless the original builderor manufacturer has specified alternative requirements.

6.2 Materials used for repairs

6.2.1 Permanent materials used in the repair are to be inaccordance with 1.3.

6.2.2 Prior to commencing any welding, the materialgrades present in the original structure in way of the repair areto be determined. Where the materials cannot be identifiedfrom the ship records, test samples may be removed forchemical analysis and mechanical testing in order to determine the material grades.

6.2.3 Temporary materials that are to be welded to themain structure to assist in executing the repairs, but removedon completion, are to be of weldable quality.

6.3 Workmanship

6.3.1 A repair method is to be established by the ship-yard or repair yard and is to be agreed by the Surveyor priorto commencing any repair work.

6.3.2 The removal of crack-like defects is to be confirmedby visual examination and surface crack detection NDE. Thismay be augmented by ultrasonic examination where severaldefects are reported at different depths at the same location.

6.3.3 The weld joint or groove shape used for the repair isto have a profile suitable for welding.

6.3.4 The weld area is to be carefully cleaned, in particular,where the material surface has been painted or has beensubjected to an oily or greasy environment.


6.4.1 On completion of welding and any post-weld heattreatment, repair welds are to be subjected to the type andextent of NDE and assessed in accordance with the accep-tance criteria specified for the original construction.

6.4.2 Where the original construction specification did notspecify NDE, the completed welds are to be, as a minimum,subject to visual examination. Consideration of other NDEtechniques is to take due cognisance of the location or therepair within the vessel.

6.4.3 Where spot NDE is applied and defects are found,the extent of NDE is to be increased to include an equalamount of weld length. Where this reveals unacceptabledefects, either the whole weld will be rejected or the extent ofinspection increased to 100 per cent examination.

6.4.4 The acceptance criteria to be applied are to generally be in accordance with the original build specifica-tion. Where conflict of requirements exist, the NDEacceptance limits for welding procedure tests specified in Ch 12,2.5.5 may be used as a minimum requirement.

6.5 Repairs to welds defects

6.5.1 Where NDE reveals unacceptable defects, theseare to be repaired in accordance with 1.15.

■ Section 7Austenitic and duplex stainlesssteel – Specific requirements

7.1 Scope

7.1.1 This Section specifies requirements for the fabrica-tion and welding of austenitic and duplex stainless steels, andis in addition to those detailed above.

7.1.2 Fabrication and welding of these materials is to bein designated areas which are separated from those used forother materials, such as carbon steels and copper alloys.Where work is performed in the same workshop as othermaterials, adequate barriers or screening are to be providedto prevent cross-contamination of different material types.

7.1.3 All tools and equipment used are to be suitable foruse on stainless steel materials. The use of tools or equipmentmade of carbon steel materials is to be avoided. It is permissible to use carbon steel tools provided that thesurfaces that come into contact with the austenitic and duplexstainless materials are protected with an austenitic or nickelbase alloy.


Requirements for Welded Construction Chapter 13Sections 5, 6 & 7


7.2 Design

7.2.1 Care is to be exercised in the weld design toprevent crevice corrosion from occurring, particularly whereaustenitic materials are used. In this respect fillet welds andpartial penetration welds are to be continuous and welded onboth sides of the joint.


7.3.1 Materials that are cold formed, such that the totalstrain exceeds 15 per cent (i.e., where the formed diameterto thickness ratio is less than 6:1) are to be subjected to asubsequent softening heat treatment in accordance with thematerial manufacturers recommendations, unless it is demonstrated by testing that the material properties areacceptable in the ‘as formed’ condition.

7.3.2 Materials may be hot formed provided that a subse-quent softening heat treatment is carried out. The formingprocess and the subsequent heat treatment are to be inaccordance with the material manufacturer’s recommenda-tions.

7.4 Fabrication and welding

7.4.1 Welding may be performed using shielded manualarc welding (SMAW), gas tungsten arc welding (GTAW),MIG/MAG welding (GMAW), flux cored arc welding (FCAW),plasma arc welding (PAW) and submerged arc welding (SAW).The use of other welding processes will be subject to specialconsideration and will require submission of the processdetails, consumables and the weld properties achieved.

7.4.2 Misalignment may be corrected by the applicationof steady even force (e.g., using hydraulic or screw-typeclamps). Hammering or heating is not permitted.

7.4.3 For full penetration welds, a backing or shieldinggas is to be provided to prevent oxidation of the root weld.The backing gas is to be maintained until completion of, atleast, the root and first fill layer. The backing gas may be omitted where the weld is back gouged or ground to removethe root weld.

7.4.4 Shielding and backing gases are to be an inert typeof high purity and oxygen free.

7.4.5 For welding of Duplex stainless, the use of backinggases that contain up to 2 per cent nitrogen is permitted.

7.4.6 Welding of duplex stainless steels without fillermetal is generally not permitted.

7.4.7 Degreasing agents, acid solutions, washing wateretc. used for cleaning and any marking crayons and paintsused are to be free of chlorides.

7.5 Repairs

7.5.1 Correction of distortion by the application of heat isnot permitted.

■ Section 8Specific requirements for weldedaluminium

8.1 Scope

8.1.1 This Section specifies requirements for the fabrica-tion and welding of aluminium alloys, and is in addition tothose detailed in this Chapter.

8.1.2 Fabrication and welding of these materials is to bein designated areas which are separated from those used forother materials, such as carbon steels, stainless steels andcopper alloys. Where work is performed in the same work-shop as other materials, adequate barriers or screening areto be provided to prevent cross-contamination of different material types.

8.1.3 All tools and equipment used are to be suitable foruse on aluminium alloy materials. The use of tools made ofcarbon steel materials is to be avoided where possible.


8.2.1 Aluminium alloys are to be subject to cold formingand cold bending only.

8.3 Fabrication and welding

8.3.1 Welding may be performed using gas tungsten arcwelding (GTAW) or metal inert gas welding (GMAW),MIG/MAG welding (GMAW), or variants thereof. The use ofother welding processes such as friction stir welding (FSW)will be subject to special consideration and will requiresubmission of the process details, consumables and the weldproperties achieved.

8.3.2 A comparison of the mechanical properties forselected welded and unwelded alloys is given in Table 13.8.1.

8.3.3 Misalignment may be corrected by the applicationof steady even force (e.g., using hydraulic or screw-typeclamps). Hammering or heating is not permitted.

8.3.4 Correction of distortion by the application of heat isnot permitted.





8.4.1 The requirements of Ch 13,1.11 and Ch 13,2.12apply; however, acceptance criteria applicable to aluminiumare to be in accordance with Table 13.8.2 and Table 13.8.3.

8.4.2 Alternative NDE acceptance criteria will be subjectto special consideration provided that they are equivalent tothese requirements.




Table 13.8.1 Minimum mechanical properties for aluminium alloys

0,2% proof stress, N/mm2 Ultimate tensile strength, N/mm2

Unwelded Welded Unwelded Welded(see Note 4) (see Note 4)

5083 O/H111 125 125 275 275

5083 H112 125 125 275 275

5083 H116/H321 215 125 305 275

5383 O/H111 145 145 290 290

5383 H116/H321 220 145 305 290

5086 O/H111 100 95 240 240

5086 H112 125 95 250 240(see Note 2) (see Note 2)

5086 H116/H321 195 95 275 240

5059 O/H111 160 160 330 330

5059 H116/H321 260 160 360 300

5456 O 125 125 285 285



5754 O/H111 80 80 190 190

6005A T5/T6 Extruded: Open Profile 215 100 260 160 (see Note 1) Extruded: Closed Profile 215 100 250 160

6061 T5/T6 Rolled 240 125 290 160(see Note 1) Extruded: Open Profile 240 125 260 160

Extruded: Closed Profile 205 125 245 160

6082 T5/T6 Rolled 240 125 280 190Extruded: Open Profile 260 125 310 190 Extruded: Closed Profile 240 125 290 190

NOTES1. These alloys are not normally acceptable for application in direct contact with sea-water. 2. See also Table 8.1.3 or Table 8.1.4 in Chapter 8. 3. The mechanical properties to be used to determine scantlings in other types and grades of aluminium alloy manufactured to National or

proprietary standards and specifications are to be individually agreed with LR, see also Ch 8,1.1.5. 4. Where detail structural analysis is carried out, ’unwelded’ stress values may be used away from heat affected zones and weld lines, see

also Pt 3, Ch 2, 1.1.3 of the Rules for Ships. 5. For thickness less than 12,5 mm, the minimum unwelded 0,2% proof stress is to be taken as 230 N/mm2 and the minimum tensile strength

is to be taken as 315 N/mm2.

Alloy Condition




Table 13.8.2 Acceptance criteria for surface imperfections of aluminium

Surface discontinuityClassification according

Acceptance criteriato ISO 6520-1



Incomplete root penetration in butt joints 4021 Not permittedwelded from one side

Surface pore 2017 d ≤ 0,3s or 0,3a or 1,5 mm (whichever is the lesser)

Linear porosity (see Note 1) 2014 Not permitted

Uniformly distributed porosity (see Note 2) 2012 ≤ 1% of area

Clustered porosity 2013 Not permitted

Continuous undercut 5011 h ≤ 0,1t or 0,5 mm (whichever is the lesser)

Intermittent undercut 5012 h ≤ 0,1t or 1,0 mm (whichever is the lesser)

Excess weld metal (see Note 3) 502 h ≤ 1,5 mm + 0,15b or 8 mm (whichever is the lesser)

Excess penetration 504 h ≤ 4 mm

Root concavity (see Note 3) 515 h ≤ 0,1t or 1 mm (whichever is the lesser)

Linear misalignment (see Notes 4 and 5) 507 h ≤ 0,1t or 1,0 mm (whichever is the lesser)

Angular misalignment 508 (see Note 6)

Symbols


NOTES1. For these acceptance criteria, linear porosity is to be considered as three aligned gas pores in a length of 25 mm.2. To be in accordance with EN ISO 10042.3. A smooth transition is required.4. Linear misalignment is to be a maximum of 0,5 mm in highly stressed areas. For other areas, the linear misalignment is to be a maximum

of 1,0 mm locally, where the sum of the length of imperfection is not more than 10% of the weld length.5. The limits for linear misalignment relate to deviations from the correct position. Unless otherwise specified, the correct position is that

when the centrelines coincide.6. Angular misalignment shall be mutually agreed between the designer and the fabricator.

■ Section 9Friction stir welding requirementsfor aluminium alloys

9.1 Scope

9.1.1 The requirements of this Section apply to the appli-cation of FSW during construction.

9.1.2 Prior to welding, the friction stir welding equipmentis to have been demonstrated as being suitable for use.

9.1.3 Qualified welding procedures that have beenapproved by LR are required. Procedures to ISO 25239-4 thatare endorsed by another Classification Society may beaccepted if they are to the satisfaction of the attendingSurveyor.

9.1.4 Welding operators are to be qualified to ISO 35239-3 standard. Where qualifications have been certified by another Classification Society, acceptance of thequalifications will be subject to document review and demonstration of knowledge of the FSW process and functionof the FSW installation.

9.2 Production quality control

9.2.1 The general requirements for quality control arespecified in ISO 35239-5.

9.2.2 Unless otherwise specified in relevant parts of theRules, the following production tests will be required.




Table 13.8.3 Acceptance criteria for internal imperfections of aluminium

Internal discontinuityClassification according

Acceptance criteria (see Note 1)to ISO 6520-1



Incomplete penetration 402 Not permitted

Single gas pore 2017 d ≤ 0,3s or 0,3a or 5 mm (whichever is the lesser)

Linear porosity 2014 Assess as lack of fusion

Uniformly distributed porosity (see Note 1) 2012 0,5 < t < 3 mm ≤ 2% of area3 < t <12 mm ≤ 4% of area12 < t < 30 mm ≤ 6% of areat > 30 mm ≤ 8% of area

Clustered porosity (see Note 1) 2013 dA ≤ 20 mm or wp (whichever is the lesser)

Elongated cavity 2015 l ≤ 0,3s or 0,3a or 4 mm (whichever is the lesser)Wormhole 2016

Oxide inclusion (see Note 2) 303 l ≤ 0,5s or 0,5a or 5 mm (whichever is the lesser)

Tungsten inclusion 3041 l ≤ 0,3s or 0,3a or 4 mm (whichever is the lesser)

Copper inclusion 3042 Not permitted

Multiple imperfections in any cross-section — The sum of the acceptable individual imperfections in any cross-section is not to exceed 0,3t or 0,3a (whichever is the lesser)

Symbols


wp = width of weld or width or height of cross-sectional areadA = diameter of area surrounding gas pores

l = length of imperfection in longitudinal direction of weld

NOTES1. Porosity is to be determined in accordance with ISO 10042. The requirements for a single gas pore are to be met by all the gas pores

within this circle. Systematic clustered porosity is not permitted.2. If several oxide inclusions l1, l2, l3, ... exist in one cross-section, then they are summed: l = l1 + l2 + l3 + ...+ ln.

9.2.3 A production test is required when there is a changein procedure, a change in tooling, after equipment repairs ormodifications, after deviation from optimum parameters aredetected, when defects are identified by non-destructive test-ing, after continuous welding of every 100 m length during asingle shift and with a maximum interval between proceduretests of 8 hours. For butt welds the production tests are toconsist of 100 per cent visual examination, two face bendtests, two root bend tests and one macro section. For thick-nesses exceeding 12 mm, sets of face and bend tests may bereplaced by side bend tests. For test assembly, see Fig.13.9.1. The production tests for other joint geometry are to beagreed between the Surveyor and the fabricator.

9.2.4 As an automated process, all essential variables areto be recorded by the FSW system. The welding operator isresponsible for ensuring that the system continues to producewelds that are in compliance with the qualified procedure.Surveyors are to be informed when the system exceeds theoperating parameters. Surveyors are periodically to review thewelding records.

9.2.5 Production welds are to be subject to 100 per centvisual examination by the fabricator and be subject to randomchecking by the Surveyor.

9.2.6 Surface and volumetric NDE testing is to be con-ducted on production welds at a frequency of two per weldedpanel or one every 100 m of weld, whichever is the greater.

9.2.7 Assessment of imperfections is to be in accordancewith ISO 35239-5 Annex A and the requirements of Table13.8.3.

9.3 Repair

9.3.1 All defective welds are to be reported to theSurveyor.

9.3.2 The manufacturer is to have an approved procedurefor the repair of defective welds.

9.3.3 Weld repairs are to be conducted by qualifiedwelders or welding operators in accordance with qualifiedweld procedures. Welding procedures and welders/operatorsare to be qualified in accordance with the requirements ofChapter 12 as appropriate to the welding process used for theweld repair.

9.3.4 All repairs are to be subject to 100 per cent visual,surface and volumetric NDE.




30 mm

30 mm

50 mm

30 mm

10 mm

30 mm

50 mm

50 mm

200 mm

500

mm

Discard

Discard

Discard

Discard

Face bend

Face bend

Root bend

Root bend

Macro

Fig. 13.9.1 Production test assembly for FrictionStir Welds

Section


2 Tests on polymers, resins, reinforcements andassociated materials

3 Testing procedures

4 Plastics pipes and fittings

5 Control of material quality for compositeconstruction


1.1 Scope

1.1.1 Provision is made in this Chapter for the manufactureand testing of plastics pipes, together with approval require-ments for base materials used in the construction or repair ofcomposite vessels, other marine structures, piping and anyassociated machinery components and fittings which are tobe certified or are intended for classification.

1.1.2 These materials and products are to be manufacturedand surveyed in accordance with the general requirements ofSections 1, 2 and 3 of this Chapter; and LR’s Materials andQualification Procedures for Ships (MQPS) Book K, seeCh 1,2.2.2, which, in addition to the test programme, alsodetails the procedures for application for approval of manufacturers and products and details of the information tobe supplied by the manufacturer.

1.1.3 For base materials, the manufacturer’s works donot require approval by Lloyd’s Register (hereinafter referredto as ‘LR’), however the Quality Control procedures must beacceptable in accordance with the appropriate Section of thisChapter.

1.1.4 Where a requirement exists for the material to beapproved, the test requirements and information to be submittedfor approval of polymers, resins, reinforcements and associ-ated materials are defined in Sections 2 and 3.

1.1.5 Specific material requirements relating to the designand manufacture of plastics pipes and fittings are indicated inSection 4, with the material requirements for hull structurescontained in Section 5.

1.1.6 For Builders constructing composite vessels,Section 5 provides the minimum material control requirementsfor acceptance of the works by LR.

1.1.7 For the purposes of these Rules a ‘plastics material’ is regarded as an organic substance which may bethermosetting or thermoplastic and which, in its finished state,may contain reinforcements or additives.

1.1.8 Materials not listed in 2.1.1 may be considered forapproval on a case-by-case basis. The approved test resultswill be listed on the issued certificate. Subject to satisfactoryservice experience and validation of approval, the materialmay be entered in 2.1.1 of the Rules.

1.2 Information on material quality andapplication

1.2.1 Where plastics products are to be classed or certified, the manufacturer is to provide the material producerwith such information as is essential to ensure that the basematerials to be used are in accordance with the approvalrequirements and the product specification. This information isto include any survey requirements for the materials.

1.3 Manufacture

1.3.1 Plastics products are to be made at works whichhave been approved (or accepted) for the type of productbeing supplied using base materials that have been approved.

1.3.2 Base materials are to be approved in accordancewith the requirements of Sections 2 and 3.

1.3.3 In order that a works can be approved (oraccepted), the manufacturer is required to demonstrate to thesatisfaction of LR that the necessary manufacturing and testingfacilities are available and are supervised by qualified personnel.A specified programme of tests is to be carried out under thesupervision of the Surveyors, and the results are to be to thesatisfaction of LR. When a manufacturer has more than oneworks, the approval (or acceptance) is only valid for the individual works which carried out the test programme.

1.3.4 In order to maintain approval, the manufacturer isrequired to confirm in writing that there have been no changesin the formulation or production process for the material inquestion and that the site of manufacture remains unchanged.

1.4 Survey procedure

1.4.1 The Surveyors are to be allowed access to all relevant parts of the works and are to be provided with thenecessary facilities and information to enable them to verifythat manufacture is being carried out in accordance with theapproved procedure. Facilities are also to be provided for theselection of test material, the witnessing of specified tests andthe examination of materials, as required by the Rules.

1.4.2 Prior to the provision of test material for accep-tance, manufacturers are to provide the Surveyors with detailsof the order, specification and any special conditions additional to the Rule requirements.

1.4.3 Before final acceptance, all test materials are to beconfirmed as typical of the manufactured product and besubmitted to the specified tests and examinations underconditions acceptable to the Surveyors. The results are tocomply with the specification and any Rule requirements andare to be to the satisfaction of the Surveyors.


Chapter 14Section 1


Plastics Materials and other Non-Metallic Materials

1.4.4 These specified tests and examinations are to becarried out prior to the despatch of finished products from themanufacturer’s works.

1.4.5 In the event of any material proving unsatisfactory,during subsequent working, machining or fabrication, it is tobe rejected, notwithstanding any previous certification.

1.5 Alternative survey procedure

1.5.1 Where materials are manufactured in quantity bysemi-continuous or continuous processes under closelycontrolled conditions, an alternative system for testing andinspection may be adopted, subject to the agreement of theSurveyors.

1.5.2 In order to be considered for approval, manufacturersare to comply with the requirements of Ch 1,2.

1.6 Post-cure heating

1.6.1 Post-cure heating is to be carried out in properlyconstructed ovens which are efficiently maintained and haveadequate means for control and recording of temperature.The oven is to be such as to allow the whole item to beuniformly heated to the necessary temperature. In the case ofvery large components which require post-cure heating, alternative methods will be specially considered.

1.7 Test material

1.7.1 Sufficient material is to be provided for the preparationof the test specimens detailed in the specific requirements. Itis, however, in the interests of manufacturers to provide additional material for any re-tests which may be necessary,as insufficient or unacceptable test material may be a causefor rejection.

1.7.2 Where test materials, (either base materials or product sample materials) are selected by the Surveyor or aperson nominated by LR, these are to be suitably identifiedby markings which are to be maintained during the prepara-tion of the test specimens.

1.7.3 All base material samples for testing are to beprepared under conditions that are as close as possible tothose under which the product is to be manufactured. Wherethis is not possible, a suitable procedure is to be agreed withthe Surveyor.

1.7.4 During production, check test samples are to beprovided as requested by the Surveyor.

1.7.5 Should the taking of these samples prove impossible,model samples are to be prepared concurrently with production.The procedure for the preparation of these samples is to beagreed with the Surveyor.

1.7.6 The dimensions, number and orientation of testspecimens are to be in accordance with the requirements ofa National or International Standard acceptable to LR.

1.8 Re-test procedure

1.8.1 Where test material fails to meet the specifiedrequirement, two additional tests of the same type may bemade at the discretion of the Surveyor.

1.8.2 Where an individual test result in a group, (minimumfive) deviates from the mean by more than two standard deviations in either the higher or lower direction, the result isto be excluded and a re-test made. Excluded results of testsare to be reported with confirmation that they have beenexcluded. Only one exclusion is acceptable in any group oftests.


1.9.1 Prior to the final acceptance, surface inspection,verification of dimensions and non-destructive examinationare to be carried out in accordance with the requirementsdetailed in Sections 3, 4 and 5 of this Chapter.

1.9.2 When there is visible evidence to doubt the soundness of any material or component, such as flaws orsuspicious surface marks, it is to be the responsibility of themanufacturer to prove the quality of the material by any suitable method.

1.10 Rectification of defective material

1.10.1 Small surface blemishes may be removed bymechanical means provided that, after such treatment, thedimensions are acceptable, the area is proved free from structural defects and the rectification has been completed tothe satisfaction of the Surveyor.

1.10.2 Repair procedures for larger defects are to beagreed with LR prior to implementation.

1.11 Identification of products and base materials

1.11.1 The manufacturer of approved materials is to identifyeach batch with a unique number.

1.11.2 The manufacturer of plastics products is to adopta system of identification which will enable all finished products to be traced to the original batches of base materials.Surveyors are to be given full facilities for tracing any component or material when required.

1.11.3 When any item has been identified by the personalmark of a Surveyor, or deputy, this is not to be removed untilan acceptable new identification mark has been made by aSurveyor. Failure to comply with this condition will render theitem liable to rejection.

1.11.4 Before any pipe or fitting is finally accepted it is tobe clearly marked by the manufacturer in at least one placewith the particulars detailed in the appropriate specific require-ments as given in Section 4.



LLOYD’S REGISTER2

Chapter 14Section 1

1.11.5 Where a number of identical items are securelyfastened together in bundles, the manufacturer need onlybrand the top item of each bundle. Alternatively, a durablelabel giving the required particulars may be attached to eachbundle.

1.12 Certification

1.12.1 Certification of the finished product is to be inaccordance with the requirements of the appropriateSections.

■ Section 2Tests on polymers, resins,reinforcements and associatedmaterials

2.1 Scope

2.1.1 This Section gives the tests and data required byLR for materials approval and/or inspection purposes on thefollowing:(a) Thermoplastic polymers.(b) Thermosetting resins.(c) Reinforcements.(d) Reinforced thermoplastic polymers.(e) Reinforced thermosetting resins.(f) Core materials.

(i) End-grain balsa.(ii) Rigid foams.(iii) Synthetic felt type materials.

(g) Machinery chocking compounds.(h) Rudder and pintle bearings.(j) Stern tube bearings.(k) Plywoods.(l) Adhesive and sealant materials.(m) Repair compounds.

2.2 Thermoplastic polymers

2.2.1 The following data is to be provided by the manu-facturer for each thermoplastic polymer:(a) Melting point.(b) Melt flow index.(c) Density.(d) Bulk density.(e) Filler content, where applicable.(f) Pigment content, where applicable.(g) Colour.

2.2.2 Samples for testing are to be prepared by mouldingor extrusion under the polymer manufacturer’s recommendedconditions.

2.2.3 The following tests are to be carried out on thesesamples:(a) Tensile stress at yield and break.(b) Modulus of elasticity in tension.(c) Tensile strain at yield and break.(d) Compressive stress at yield and break.(e) Compressive modulus.(f) Temperature of deflection under load.(g) Determination of water absorption.

2.3 Thermosetting resins

2.3.1 The data listed in Table 14.2.1 is to be provided bythe manufacturer for each thermosetting resin.

2.3.2 Cast samples are to be prepared in accordancewith the manufacturer’s recommendations and are to becured and post-cured in a manner consistent with theintended use. The curing system used and the ratio of curingagent (or catalyst) to resin are to be recorded. Where post-cure conditions equivalent to ambient-cure conditionsapply, see 3.2.2 and 3.2.3.





Type of resin

Data Polyester(see Note 3 Epoxide Phenolic

for vinylester)

Specific gravity required required requiredof liquid resin

Viscosity required required required

Gel time required required not applicable

Appearance required required required

Mineral content required required not applicable(see Note 1) (see Note 2)

Volatile content required not applicable not applicable

Acid value required not applicable not applicable

Epoxide content not applicable required not applicable

Free phenol not applicable not applicable required

Free formaldehyde not applicable not applicable required

NOTES1. This is to be the total filler in the system, including thixotrope,

filler, pigments, etc., and is to be expressed in parts by weightper hundred parts of pure resin.

2. If the resin is pre-filled, the mineral content is required.3. Vinylesters are to be treated as equivalent to polyesters.

Table 14.2.1 Data requirements for thermosettingresins

2.3.3 The following are to be determined using thesesamples:(a) Tensile strength (stress at maximum load) and stress at

break.(b) Tensile strain at maximum load.(c) Tensile secant modulus at 0,5 per cent and 0,25 per cent

strain respectively.(d) Temperature of deflection under load.(e) Barcol hardness.(f) Determination of water absorption.(g) Volume shrinkage after cure.(h) Specific gravity of cast resin.

2.3.4 In addition, for gel coat resins the stress at breakand modulus of elasticity in flexure are to be determined.

2.3.5 Where resins which have been modified by theaddition of waxes or polymers, for example ‘low styreneemission or air inhibited’ materials, it is to be confirmed thatthe use of such resins will not result in poor interlaminaradhesion when interruptions to the laminating process occur.The test procedure is to be as follows:(a) A conventional room temperature curing catalyst/

accelerator system is to be used with the resin for laminate preparation.

(b) A laminate of 25 to 35 per cent glass content in mass isto be prepared using two plies of 450 g/m2 choppedstrand mat. The laminate is to be prepared at ambienttemperature (18° to 21°C). The laminate is to be allowedto stand for a minimum of four days but no longer than 6 days at ambient temperature.

(c) A further two plies of 450 g/m2 chopped strand mat areto be laminated onto the exposed surface and cured atambient temperature for 24 hours. The finished laminateis then to be post-cured at 40°C for 16 hours. Thefinished laminate is to have a glass content of 25 to 35 per cent.

(d) After cooling, the apparent interlaminar shear strength ofthe laminate is to be determined in accordance with ISO 14130; the minimum value is given in Table 14.5.5.Before testing the samples shall be conditioned at 23°Cand relative humidity of 50 per cent for a period of 88 hours before testing.

(e) If the tests are undertaken at the resin manufacturer’sown laboratory, the individual test values are to bereported and the broken test specimens retained forexamination by LR.

Alternative test procedures will be considered with prioragreement.

2.4 Reinforcements

2.4.1 The following data is to be provided, where applicable, for each type of reinforcement:(a) Reinforcement type.(b) Fibre type for each direction.(c) Fibre tex value.(d) Fibre finish and/or treatment.(e) Yarn count in each direction.(f) Width of manufactured reinforcement.(g) Weight per unit area of manufactured reinforcement.(h) Weight per linear metre of manufactured reinforcement.

(j) Compatibility (e.g. suitable for polyesters, epoxides,etc.).

(k) Constructional stitching – details of yarn, specific gravity,type, frequency and direction.

(l) Weave type.(m) Binder type and content.(n) Density of the fibre material.

2.4.2 Tests of the mechanical properties are to be madeon laminate samples containing the reinforcement andprepared as follows:(a) an approved resin of suitable type is to be used;(b) a minimum of three layers of the reinforcement is to be

laid with parallel ply to give a laminate not less than 4 mm thick;

(c) the weights of resin and reinforcement used are to berecorded together with the measured thickness of thelaminate, including the measured weight per unit area ofthe reinforcement used;

(d) for glass reinforcements, the glass/resin ratios, byweight, as shown in Table 14.2.2 are to be used;

(e) for reinforcement type other than glass, a fibre volumefraction, as shown in Table 14.2.3, is to be used.

2.4.3 Rovings intended for filament winding are to betested as unidirectional rovings.

2.4.4 The following tests as defined in Section 3 are to bemade on the samples:(a) Tensile strength (stress at maximum load).(b) Tensile strain at break.(c) Tensile secant modulus at 0,5 per cent and 0,25 per cent

strain respectively.(d) Compressive strength (stress at maximum load).(e) Compressive modulus.(f) Flexural strength (stress at maximum load).(g) Modulus of elasticity in flexure.(h) Apparent interlaminar shear.



LLOYD’S REGISTER4

Chapter 14Section 2

Table 14.2.2 Glass fraction by weight for differentreinforcement types

Reinforcement typeGlass fractionnominal values

Unidirectional 0,60

Chopped strand mat 0,30

Woven roving 0,50

Woven cloth 0,50

Composite roving (see Note) 0,45

Gun rovings 0,33

±45° stitched parallel plied roving 0,50

Triaxial parallel plied roving 0,50

Quadriaxial parallel plied roving 0,50

NOTEContinuous fibre reinforcement with attached chopped strand mat.

(j) Fibre content.(k) Determination of water absorption.

2.4.5 The laminate is to be tested in air in the directionsindicated by Table 14.2.4.

2.4.6 Additionally, tests in 2.4.4(c) and (f) are to berepeated, in one direction only, after immersion in fresh waterat 35°C for 28 days with the exception of 2.4.4(k).

2.5 Reinforced thermoplastic polymers

2.5.1 Thermoplastic polymers intended for use with reinforcements are to be tested in accordance with 2.2.1 to2.2.3.

2.5.2 A laminate is to be prepared using the polymer andan approved reinforcement in accordance with a manufacturingspecification. The laminate is to be tested in accordance withthe appropriate requirements of 2.4.4. Testing may beconfined to one direction only.

2.6 Reinforced thermosetting resins

2.6.1 Thermosetting resins intended for use with re-inforcements are to be tested in accordance with 2.3.1 to2.3.4.

2.6.2 No further tests are required for gel coat resins.

2.6.3 For laminating resins, a laminate is to be preparedusing the resin and an approved reinforcement as follows:(a) For polyester resins, chopped strand mat.(b) For epoxide resins, a balanced woven roving.(c) For phenolic resins, a balanced woven material.

2.6.4 The laminate is to be tested in accordance withprocedures outlined in MQPS Book K procedure 14-1 and2.4.4 in one fibre direction only.

2.7 Core materials

2.7.1 General requirements. The following data is to beprovided for each type of core material:(a) Type of material.(b) Density.(c) Description (block, scrim mounted, grooved).(d) Thickness and tolerance.(e) Sheet/block dimensions.(f) Surface treatment.

2.7.2 Manufacturers are required to provide a full application procedure for use of the product.

2.8 Specific requirements for end-grain balsa

2.8.1 The supplier is to provide a signed statement thatthe balsa (ochroma lozopus) is cut to end-grain, is of goodquality, being free from unsound or loose knots, holes, splits,rot, pith and corcho, and that it has been treated againstfungal and insect attack, shortly after felling, followed byhomogenisation, sterilisation and kiln drying to an averagemoisture content of no more than 12 per cent.

2.8.2 The following tests are to be carried out on thevirgin material, both parallel to and perpendicular to the grain:(a) Compressive strength (stress at maximum load).(b) Compressive modulus of elasticity.(c) Tensile strength (stress at maximum load).The density of the virgin material is also to be tested.

2.8.3 Where the balsa is mounted on a carrier material(e.g. scrim), any adhesive used is to be of a type compatiblewith the proposed resin system.

2.8.4 Core shear properties are to be determined accordingto the requirements of 3.8.1.


Chapter 14Section 2



Type of reinforcement Test orientations

Unidirectional 0°

Chopped strand mat any directionGun roving

Woven rovingWoven cloth 0° and 90°Composite roving

± 45° parallel plied rovingTriaxial plied roving 0°, 45°, 90° and –45°Quadriaxial plied roving

Table 14.2.4 Fibre orientations in reinforced testspecimens

Table 14.2.3 Content by volume for different reinforcement types

Reinforcement typeContent by volume

nominal values

Unidirectional 0,41

Chopped strand mat 0,17

Woven roving 0,32

Woven cloth 0,32

Composite roving (see Note) 0,28

Gun rovings 0,19

±45° stitched parallel plied roving 0,32

Triaxial parallel plied roving 0,32

Quadriaxial parallel plied roving 0,32

NOTEThe volume content may be converted to weight fractions by use ofthe formula:

WF = VF DF/(DF VF + DR VR)where

WF = fibre fraction by weightDF = density of fibreDR = density of cured resinVF = fibre fraction by volumeVR = resin fraction by volume

2.9 Specific requirements for rigid foams (PVC,Polyurethane and other types)

2.9.1 The foam is to be of the closed cell type andcompatible with the proposed resin system (e.g., polyester,epoxide, etc.).

2.9.2 Foams are to be of uniform cell structure.

2.9.3 Data is to be provided on the dimensional stabilityof the foam by measurement of the shrinkage.

2.9.4 The following test data is to be submitted for eachtype of foam:(a) Density.(b) Tensile strength (stress at maximum load).(c) Tensile modulus of elasticity.(d) Compressive strength (stress at maximum load).(e) Compressive modulus of elasticity.

2.9.5 Core shear properties are to be determined according to the requirements of 3.8.1.

2.9.6 Additionally, the compressive properties (see2.9.4(d) and (e)) are to be determined at a minimum of fivepoints over the temperature range ambient to maximumrecommended service or 70°C, whichever is the greater.

2.10 Synthetic felt type materials with or withoutmicrospheres

2.10.1 For materials of this type, the following data isrequired in addition to the requirements of 2.7.1:(a) Fibre type.(b) Width.(c) Width of finished material.(d) Weight per unit area of the manufactured material.(e) Weight per linear metre of the manufactured material.(f) Compatibility.(g) Details of the method of combining.

2.10.2 A laminate of the material is to be prepared using asuitable approved resin under conditions recommended bythe manufacturer.

2.10.3 The following properties are to be determined:(a) Tensile strength (stress at maximum load).(b) Tensile strain at break.(c) Modulus of elasticity in tension or secant modulus at

0,25 per cent and 0,5 per cent strain.(d) Compressive strength (stress at maximum load).(e) Compressive modulus.(f) Flexural strength (stress at maximum load).(g) Modulus of elasticity in flexure.(h) Fibre content.(j) Water absorption.

2.10.4 In the case of anisotropic materials (e.g., wherecombined with other reinforcements) the tests listed in 2.10.3are to be conducted in the 0°, 90° directions and in any otherreinforcement direction.

2.10.5 Additionally, the tests listed in 2.10.3 are to berepeated after immersion in fresh water at 35°C for 28 days.For anisotropic materials, the requirement is for this test to becarried out in one direction only.

2.10.6 The shear properties (of the resin filled system) areto be determined according to 3.8.1.

2.11 Machinery chocking compounds (resinchocks)

2.11.1 Thermosetting materials for filling the spacebetween the base of machinery and its foundation where themaintenance of accurate alignment is necessary are to beapproved by LR before use.

2.11.2 Approval will be considered by LR for use under thefollowing service conditions:• Loading of 3,5 N/mm2

(max) for a temperature not exceeding 60°C.• Loading of 2,5 N/mm2

(max) for a temperature not exceeding 80°C.• Other loading conditions.

2.11.3 The exotherm temperature, defined as the maximum temperature achieved by the reacting resin underconditions equivalent to those of intended use, is to be determined according to a procedure approved by LR.

2.11.4 The following properties are to be determined onchock material cured at the measured exotherm temperature:(a) The impact resistance (Izod).(b) Hardness.(c) Compressive strength (stress at maximum load) and

modulus of elasticity.(d) Water absorption.(e) Oil absorption.(f) Heat deflection temperature.(g) Compressive creep is to be measured according to 3.9.4.(h) Curing linear shrinkage.(j) Flammability.

2.11.5 The chocking compound approval is contingent onthe material achieving the minimum exotherm value as specified when used on an installation under practical conditions.

2.11.6 Where the resin chock is to be used for installationof sterntubes and sternbushes in addition to the requirementsof 2.11.4, the tensile strength and modulus of elasticity intension are to be measured.

2.11.7 The manufacturer’s installation procedure is requiredto be documented and is to be to the satisfaction of LR.

2.12 Rudder and pintle bearings

2.12.1 Materials used for rudder and pintle bearings are tobe approved by LR before use.



LLOYD’S REGISTER6

Chapter 14Section 2

2.12.2 Initial approval is to be based on a review of thefollowing physical properties of the material:(a) Compressive strength (stress at maximum load) and

modulus of elasticity.(b) Tensile strength (stress at maximum load) and modulus

of elasticity.(c) Shear strength (stress at maximum load).(d) Impact strength.(e) Swelling in oil and in water.(f) Hardness.

2.12.3 Additionally, friction data is to be provided underboth wet and dry conditions.

2.12.4 Furthermore, the installation instructions (especiallyrecommended clearances) are to be reviewed by LR prior toprovisional approval being given.

2.12.5 If the above data is satisfactory, the material will beprovisionally approved until sufficient service experience hasbeen gained.

2.13 Sterntube bearings

2.13.1 Materials used for sterntube bearings are to beapproved by LR before use.

2.13.2 Approval is to be based on a review of the physicalproperties as given by 2.12.2.

2.13.3 Friction data is to be provided under the lubricationsystem(s) proposed for the material(s).

2.14 Plywoods

2.14.1 All plywoods are to be approved to BS 1088 orequivalent National or International Standard in accordancewith LR’s Type Approval Procedure.

2.14.2 For structural applications in the marine environ-ment, a minimum timber rating of moderate durabilityaccording to BS 1088-1 and BS 1088-2 is required.

2.14.3 Enhancement of durability by use of preservatives ispermitted, subject to each veneer layer being treated with arecognised preservative.

2.14.4 Where Okoume, as specified by BS 1088 is involved,(i.e. non-durable timber classification) this may only be usedfor marine structures subject to the specific application beingacceptable to LR.

2.15 Adhesive and sealant materials

2.15.1 Materials of these types are to be accepted by LRbefore use.

2.15.2 The requirements for acceptance are dependent onthe nature of the application.

2.15.3 In the first instance, the manufacturer is to submitfull details of the product, procedure for method of use(including surface preparation) and the intended application.After review of these details, LR will provide a specific testschedule for confirmation of the material’s properties.

2.15.4 Any acceptance granted will be limited to specificapplications and will be contingent on the instructions for usebeing adhered to.

2.16 Repair compounds

2.16.1 Materials used for repairs are to be accepted by LRbefore use.

2.16.2 For acceptance purposes, the manufacturer is tosubmit full product details, and user instructions, listing thetypes of repair for which the system is to be used togetherwith details of any installer accreditation schemes.

2.16.3 Dependent on the proposed uses, LR may requiretesting in accordance with a specified test programme.

2.16.4 Materials will not be accepted for the following usesunless specific evidence of their suitability is provided:(a) Any component in rubbing contact.(b) Any component subject to dynamic cyclic loading.(c) Any pressure part in contact with gas or vapour.(d) Any pressure part in contact with liquid above 3,5 bar.(e) Any component where operating temperature exceeds

90°C.All uses of materials of these types are subject to the discretion of the Surveyor.

■ Section 3Testing procedures

3.1 General

3.1.1 This Section gives details of the test methods to beused for base materials and on finished plastics productssuch as fibre reinforced plastics (FRP) piping and any testingrequired in the construction of composite vessels.

3.1.2 In general, testing is to be carried out by a competent independent test house which, at the discretion ofLR, may or may not require witnessing by the Surveyor.

3.1.3 Alternatively, testing may be carried out by themanufacturer subject to these tests being witnessed by theSurveyor.

3.1.4 All testing is to be carried out by competent personnel.

3.1.5 Unless specified otherwise, testing is to be carriedout in accordance with a recognised ISO Standard, where oneexists, and all test programmes are to have written procedures.





3.4 Testing

3.4.1 Strain measurement is to be made by the use of asuitable extensometer or strain gauge.

3.4.2 The rate of strain is to be in accordance with theappropriate ISO standard.

3.4.3 The number of test specimens from each sampleto be tested is to be in accordance with the ISO standard. Formechanical testing this is five.

3.5 Discarding of test specimens

3.5.1 If a test specimen fails because of faulty prepara-tion or incorrect operation of the testing machine, it is to bediscarded and replaced by a new specimen.

3.5.2 In addition, if the deviation of one result in a groupof five exceeds the mean by more than two standard deviations, that result is to be discarded and one further specimen tested, see 1.8.1 and 1.8.2.

3.6 Reporting of results

3.6.1 All load/displacement graphs and tabulated resultsare to be reported, including mean values and the calculatedstandard deviation.

3.6.2 Additionally, full details of the sample and specimenpreparation are to be provided including (where applicable):(a) Catalyst/accelerator or curing agent types and mix ratio.(b) Weights of resins, and/or reinforcements used.(c) Casting/laminate dimensions.(d) Number of layers of reinforcement used.(e) Curing/post-curing conditions.

3.7 Tests for specific materials

3.7.1 The data requirements in 2.2 and 2.3 for thermo-plastic or thermosetting resins or polymers are to bedetermined in accordance with suitable National orInternational Standards.

3.7.2 Recognised Standards to which specimens of unreinforced thermoplastic resins are to be tested are listedin Table 14.3.1.

3.7.3 Test standards for unreinforced cast thermo-setting resins are given in Table 14.3.2.

3.7.4 The Standards to which laminate specimens of anytype are to be tested are listed in Table 14.3.3.

3.1.6 Alternatively, testing may be carried out in accordance with a National Standard provided that itconforms closely to an appropriate ISO standard and subjectto prior agreement with the Surveyor.

3.1.7 Mechanical properties are to be established usingsuitable testing machines of approved types. The machinesand other test equipment are to be maintained in a satisfactoryand accurate condition and are to be recalibrated at approximately annual intervals. Calibration is to be undertakenby a nationally recognised authority or other organisation ofstanding and is to be to the satisfaction of the Surveyor. Arecord of all calibrations is to be kept available in the testhouse. The accuracy of test machines is to be within ±oneper cent.

3.2 Preparation of test samples

3.2.1 Thermoplastic samples are to be prepared in accordance with the manufacturer’s recommendations formoulding. For finished products, samples are to be taken fromthe product during production in accordance with the manufacturer’s quality plan, but where this is impractical,separate test samples are to be prepared in a manner identical with that of the product.

3.2.2 Samples of thermosetting resins are to be preparedusing the curing system recommended by the manufacturerand identical with that used for the finished product.

3.2.3 The post curing conditions for samples of thermosetting resins are to be as recommended by the manufacturer and identical with those used for the finishedproduct. Where the samples are made for the generalapproval of a resin, the post curing conditions are to be thosein which the resin is intended to be used.

3.2.4 Where curing of the product is intended to takeplace at room temperature, the sample is to be allowed tocure at room temperature (18 to 21°C) for 24 hours followedby a post-cure at 40°C for 16 hours.

3.2.5 Where a reinforcement is to be used, the ratio ofreinforcement to resin or polymer is to be nominally the sameas that of the finished product or in accordance with Table 14.2.2 or 14.2.3.

3.2.6 Where laminates are prepared specifically forapproval test purposes, the reinforcement is to be laid parallel plied.

3.3 Preparation of test specimens

3.3.1 The test specimen is to be prepared in accordancewith the appropriate ISO standard and the requirements ofthis Section.

3.3.2 Precautions are to be taken during machining toensure that the temperature rise in the specimen is kept to aminimum.


Plastics Materials and other Non-Metallic Materials Chapter 14Section 3

LLOYD’S REGISTER8

3.8 Structural core materials

3.8.1 Initially, the core shear strength and modulus are tobe determined by ISO 1922:2001 or ASTM C273/C273M.Test sandwich panels are then to be prepared and subjectedto four-point flexural tests to determine the apparent shear properties according to ASTM C393/C393M:06 (short beam)at two representative thicknesses (i.e., 15 mm and 30 mm).Testing is to be carried out at ambient temperature and at70°C. The following requirements are to be observed:

(a) Each skin is to be identical and have a thickness notgreater than 21 per cent of the nominal core thickness.For hand laid constructions, each skin is to comprise alightweight chopped strand mat reinforcement (300 g/m2)consolidated at a glass content, by weight, of 0,3 againstthe core, plus the required number of woven reinforcements consolidated, using an isophthalicpolyester resin, to give a minimum glass content, byweight, of 0,5.

(b) The method of construction of the sandwich laminate isto reflect the core material manufacturer’s instructionsfor use, i.e., application of bonding paste, surface primeror any other recommended system.

(c) Where vacuum bagging techniques or equivalentsystems are used, these will be subject to individualconsideration.

(d) All resins and reinforcements are to hold current LRapproval.

(e) Curing conditions are to be in accordance with 3.2.3 and3.2.4.

(f) The dimensions of the test samples should be based onthe requirements of ASTM C393 Paragraph 5.1, and theratio parameters as indicated in ASTM C393 Paragraph5.2, using a proportional limit stress (F) for the wovenroving skins of 130 N/mm2 and a span (a2) of not lessthan 400 mm.


Chapter 14Section 3



Test Standard

Tensile properties ISO 527-2:1993 Test speed = 5 mm/minSpecimen 1A or 1B

Flexural properties ISO 178:2001 Test speed = mm/min

Water absorption ISO 62:2008 Method 1

Temperature of ISO 75-2:2004 Method Adeflection underload

Compressive ISO 604:2002 Test speed – as for ductile properties materials

NOTES1. Water absorption – result to be expressed as milligrams.2. Tensile modulus values are to be determined using an

extensometer which may be removed for strain to failure.

Thickness2

Table 14.3.1 Tests for unreinforced thermoplasticresins

Table 14.3.2 Tests on unreinforced cast thermosetresin specimens

Test Standard

Tensile properties ISO 527-2:1993 Test speed = 5 mm/minSpecimen 1A or 1B



Temperature of ISO 75-2:2004 Method Adeflection underload

Compressive ISO 604:2002 Test speed = 1 mm/minproperties

NOTES1. ISO 62:2008 – where resins are intended for use under

ambient conditions to avoid additional post-curing, therequirement in ISO 62:2008 for pre-drying the test specimenat 50°C is to be omitted. The test result is to be expressedas mg of water.

2. ISO 527-2:1993 – tensile properties are to be measuredusing extensometry.

Thickness2

Test Standard

Tensile properties ISO 527-4:1997 Test speed = 2 mm/minSpecimens Types II or III


Method A

Compressive ISO 604:2002 Test speed = 1 mm/minproperties

Interlaminar shear ISO 14130:1997


Glass content ISO 1172:1996

NOTES1. ISO 62:2008 – where resins are intended for use under

ambient conditions to avoid additional post-curing, therequirement in ISO 62:2008 for pre-drying the test specimenat 50°C is to be omitted. The test result is to be expressedas mg of water.

2. ISO 527-4:1997 – tensile properties are to be measuredusing extensometry.

3. Tensile modulus values are to be determined using an extensometer which may be removed for strain to failure.

Thickness2

Table 14.3.3 Tests on laminate specimens

3.8.2 For each type of test sample, the following data areto be reported, together with the submission of a representativetest sample showing the mode of failure for each density ofcore material:(a) Skin and core thickness, and core type and density.(b) Resin/catalyst/accelerator ratio.(c) Skin construction, including types and weight of

reinforcements, resin(s), etc.(d) Details of production method and curing conditions

(temperature and times).(e) Where additional preparation of the foam is involved, for

example the use of primers or bonding pastes, full detailsare to be provided.

(f) Actual span between base supports for each type of testsample.

3.8.3 The following requirements apply to end-grainbalsa:(a) The data requirements of 2.7.1 are to be provided,

where applicable, according to suitable National orInternational Standards.

(b) The balsa is to be tested according to the requirementsof 3.8.1.

(c) The test methods for balsa are given in Table 14.3.4.

3.8.4 The following requirements apply to rigid foams:(a) The data requirements of 2.7.1 are to be provided in

accordance with a suitable National or InternationalStandard.

(b) The foam is to be tested according to the requirementsof 3.8.1.

(c) The test methods for rigid foams are to be in accordancewith Table 14.3.4.

3.8.5 The following requirements apply to synthetic felttype materials:(a) The data requirements of 2.10.1 are to be provided

according to suitable National or International Standards.(b) The material is to be tested according to the require-

ments of 3.8.1, with the following modifications:(i) The core of the laminate test sandwich panel is

to be prepared with a fibre content as recom-mended by the manufacturer.

(ii) The felt fibre/resin ratio is to be stated.

(iii) The required test thicknesses of the cores are tobe changed from 30 mm and 15 mm to 12 mmand 6 mm respectively.

(c) The prepared laminate of the base material is to be ofminimum thickness 3,5 mm with a minimum of threelayers.

(d) The specified tests on the laminate (see 2.10.3) are to beconducted according to the requirements of Table 14.3.3.

3.9 Machinery chocking compounds

3.9.1 Test samples of the cured chock resin are to beprepared under ambient conditions and then post-cured atthe exotherm temperature as determined in 2.11.3.

3.9.2 The specified properties are to be determined asrequired by Table 14.3.5.

3.9.3 The percentage linear shrinkage of cured materialis to be measured.

3.9.4 Creep is to be measured according to the followingmethod:(a) A 25 mm x 20 mm diameter parallel faced cylinder is to

be pre-loaded against a steel base at 2,5 N/mm2 or 3,5 N/mm2, or at the specified higher loading condition,at ambient temperature for 16 hours.

(b) The temperature is to be increased at the rate of 8°C perhour until the service temperature (60°C or 80°C) isreached.

(c) During this time, the creep of the cylinder is to bemeasured at 15 minute intervals.

(d) The temperature and loading are to be maintained for aminimum of 100 days measuring the creep at intervalsof 24 hours.

(e) A plot of creep in mm (linear scale) against time (logscale), together with full experimental details, is to beprovided for review by LR.




Chapter 14Section 3

Table 14.3.5 Tests for machinery chockingcompounds

Test Standard

Izod Impact Resistance ISO 180-2000 Unnotched

Barcol hardness ASTM D2583-07 or BS 2782 part 10 Method 1001

Compressive strength ISO 604:2002Test speed = 1 mm/min

Water absorption ISO 62:2008 Method 125 mm x 20 mm cylinder (to constant weight)

Oil absorption (light machine) ISO 175:199925 mm x 20 mm cylinder(to constant weight)

Temperature of deflection ISO 75-2 Method Aunder load

Test Standard

Density ISO 845:2006

Tensile properties ASTM C297/C297M:04

Test speed = mm/min

Compressive properties ISO 844:2007

Test speed = mm/min

Shear properties ISO 1922:2001Test speed = 1mm/min

Thickness10

Thickness10

Table 14.3.4 Tests on end-grain balsa

4.2.3 Any alteration of the component materials or manufacturing operations from those used in the designsubmission will necessitate a completely new submission.

4.2.4 If the piping manufacturer anticipates the possibleuse of alternative materials, these should be listed in thedesign submission. Proof that the modified product will meetthe specified requirements will be needed prior to its use.

4.3 Manufacture

4.3.1 Plastics pipes and fittings intended for use in Class I, Class II and Class III systems are to be manufacturedat facilities approved by LR, using materials approved by LR.

4.3.2 A Manufacturing Specification is to be submitted.This is to contain details of the following:(a) All constituent materials.(b) Manufacturing procedures such as lay-up sequence or

wind angle, the ratios of curing agent to resin and reinforcement to resin, the laminate thickness, themandrel dwell time (initial cure) and the cure and post-cure conditions.

(c) Quality control procedures including details andfrequency of tests on the incoming materials, tests madeduring production and on the finished piping.

(d) Acceptance standards and tolerances, including alldimensions.

(e) Procedures for cosmetic repair.(f) System for traceability of the finished piping to the

batches of raw materials.(g) Method of bonding pipes and fittings.

4.3.3 Details of all raw materials are to be submitted forapproval and are to be in accordance with the ManufacturingSpecification and the design submission.

4.3.4 All batches of raw materials are to be provided withunique identifications by their manufacturers.

4.3.5 No batch of material is to be used later than its dateof expiry.

4.3.6 The piping manufacturer is to ensure that allbatches of materials are used sequentially.

4.3.7 The piping manufacturer is to maintain records ofthe amounts of resin and reinforcement used, in order toensure that the proportions remain within the limits set in theManufacturing Specification.

4.3.8 Records are to be kept of the wind angle and/or theorientation of the reinforcement.

4.3.9 The piping manufacturer is to ensure that each itemof piping is traceable to the batch or batches of material usedin its manufacture. The unique identifications referred to in4.3.4 are to be included on all documents.

4.3.10 The curing oven is to be suitable for the intendedpurpose and all pyrometric equipment is to be calibrated atleast annually and adequate records maintained.




3.10 Rudder and pintle bearings

3.10.1 All mechanical properties as required by 2.12 are tobe measured according to suitable National or InternationalStandards.

3.10.2 Frictional properties are to be determined accordingto a method agreed with LR.

3.11 Sterntube bearings

3.11.1 The requirements for sterntube bearings are asdefined in 2.13.

■ Section 4Plastics pipes and fittings

4.1 Scope

4.1.1 This Section gives the general requirements forplastics pipes and fittings, with or without reinforcement,intended for use in the services listed in the relevant Rulesdealing with design and construction. Hoses and mechanicalcouplings are not covered by these requirements.

4.1.2 Pipes and fittings intended for application in Class I, Class II and Class III systems for which there are Rulerequirements, are to be manufactured in accordance with therequirements of Section 1 and this Section.

4.1.3 As an alternative to 4.1.2, plastics pipes and fittingswhich comply with National or proprietary specifications maybe accepted, provided that the specifications give reasonableequivalence to the requirements of this Section or, alterna-tively, are approved for a specific application. The survey andcertification are however to be carried out in accordance withthe requirements of this Section.

4.2 Design requirements

4.2.1 The requirements for design approval are detailedin the relevant Rules.

4.2.2 The design submission is to include a materials listwith confirmation that the materials listed have properties andcharacteristics conforming with those values used in thedesign submission. As a minimum, the details given shouldinclude the following:(a) Resin.(b) Accelerator (type and concentration).(c) Catalyst or curing agent (type and concentration).(d) Reinforcement.(e) Cure/post-cure conditions.(f) Resin/reinforcement ratio.(g) Wind angle (or lay-up sequence) and orientation.(h) Dimensions and tolerances.This submission is to include similar details for the fittingstogether with a description of the method of attachment ofthe fittings to the pipes.


4.7.3 For reinforced thermoset pipes,the resin manufac-turer is to determine, on samples taken from each batch, atleast the following:(a) All resins:

(i) Viscosity.(ii) Gel time.(iii) Filler content, where applicable.

(b) Polyester resins:(i) Type (orthophthalic, isophthalic, etc.).(ii) Volatiles content.(iii) Acid value.

(c) Epoxide resins:(i) Free epoxide content.

(d) Phenolic resins:(i) Free phenol content.(ii) Free formaldehyde content.

4.7.4 The values obtained are to comply with the require-ments of the Manufacturing Specification.

4.7.5 Where the resin manufacturer mixes batches, boththe original batches and the mixed batch are to be tested inaccordance with 4.7.1 to 4.7.3 as appropriate. The mixedbatch is then to be given a unique batch number.

4.7.6 The polymer or resin manufacturer is to demon-strate that each batch of polymer or resin satisfies therequirement for temperature of deflection under load and thisis not to be less than 80°C.

4.7.7 These measurements should be repeated on eachbatch by the piping manufacturer. Where this is not done, LRmay require that the tests be made on a random basis by anindependent laboratory.

4.7.8 The piping manufacturer is to confirm, by means oftests on at least one batch in twenty, that the temperature ofdeflection under load exceeds the specified minimum undermanufacturing conditions.

4.7.9 Where reinforcements are used, at least the followingare to be recorded, where applicable:(a) Tex of yarn(s) or roving(s).(b) Ends per 100 mm in all reinforcement orientations.(c) Weight per square metre.(d) Binder/size content.(e) Stitch type and count.(f) Type of fibre used.(g) Surface treatment and/or finish.

4.7.10 All items in 4.7.9 are to comply with the ManufacturingSpecification.

4.7.11 The piping manufacturer is to maintain accuraterecords of resin and glass usage and is to calculate theresin/glass ratio on an ongoing basis.

4.7.12 During manufacture of the piping, apart from therequirements of 4.7.5, 4.7.6 and 4.7.8, tests are to be carriedout on the constituents and final product in accordance withTable 14.4.1.

4.7.13 The standards of acceptance are those listed in theManufacturing Specification approved by LR.




Chapter 14Section 4

4.3.11 The temperature of the pipe or fitting is to becontrolled and recorded by the attachment of suitably placedthermocouples.

4.4 Quality assurance

4.4.1 The piping manufacturer is to have a quality assurance system approved to ISO 9001 or equivalent. Thissystem should ensure that the pipes and fittings are producedwith uniform and consistent mechanical and physical properties in accordance with acceptable standards.


4.5.1 Dimensions and tolerances are to conform to theManufacturing Specification.

4.5.2 The wall thicknesses of the pipes are to bemeasured at intervals around the circumference and along thelength in accordance with an appropriate National Standard.The thicknesses are to accord with the ManufacturingSpecification.

4.5.3 The responsibility for maintaining the required tolerances and making the necessary measurements restswith the manufacturer. Occasional checking by the Surveyordoes not absolve the manufacturer from this responsibility.

4.6 Composition

4.6.1 The composition of the pipes and fittings is to be inaccordance with the Manufacturing Specification.

4.6.2 Where alternative materials are used (see 4.2.4), themanufacturer is to demonstrate to the Surveyor’s satisfaction,and prior to their introduction, their suitability with respect tothe performance of the piping. Otherwise, full testing as specified in 4.7 will be required.

4.7 Testing

4.7.1 For thermoplastic pipes, the polymer manufactureris to make the following measurements on samples takenfrom each batch:(a) Melting point.(b) Melt flow index.(c) Density.(d) Filler/pigment content, where applicable.(e) Tensile stress at yield and break.(f) Tensile strain at yield and break.

4.7.2 The values obtained are to be certified by the polymer manufacturer.

4.10 Repair procedure

4.10.1 Repairs are not allowed, with the exception ofminor cosmetic blemishes as detailed in 1.10.1.

4.10.2 A repair procedure for these minor blemishes is tobe included in the Manufacturing Specification.

4.11 Identification

4.11.1 All piping is to be identified in such a manner thattraceability to all the component materials used in its manufacture is ensured. The Surveyor is to be given full facilities for tracing the material when required.

4.11.2 Pipes and fittings are to be permanently marked bythe manufacturer by moulding, hot stamping or by any othersuitable method, such as printing, in accordance with 1.11.The markings are to include:(a) Identification number, see 4.11.1.(b) LR or Lloyd’s Register, and the abbreviated name of LR’s

local office.(c) Manufacturer’s name or trademark.(d) Pressure rating.(e) Design standard.(f) Material system with which the piping is made.(g) Maximum service temperature.

4.12 Certification

4.12.1 The manufacturer is to provide the Surveyor withcopies of the test certificates or shipping statements for allmaterial which has been accepted.

4.12.2 Each test certificate is to contain the followingparticulars:(a) Purchaser’s name and order number.(b) If known, the contract number for which the piping is

intended.(c) Address to which piping is despatched.(d) Type and specification of material.(e) Description and dimensions.(f) Identification number, see 4.11.1.(g) Test results.

■ Section 5Control of material quality forcomposite construction

5.1 Scope

5.1.1 This Section gives the general requirements forcontrol of material quality when used in the construction ofcomposite craft.

5.1.2 For composite craft built under the Rules, thesurvey of materials is to be conducted in accordance with therequirements of Sections 1 to 3 and this Section.




4.7.14 At the Surveyor’s discretion, sections of pipe are tobe subjected to hydraulic bursting tests and/or measurementsof axial strength.

4.7.15 If the batch of resin or polymer, or the curing agent,or their ratio is changed during manufacture of a batch ofpipes, at least two additional measurements of the gel timeare to be carried out during each shift.


4.8.1 All pipes and fittings are to be visually examinedand are to be free from surface defects and blemishes.

4.8.2 The pipes are to be reasonably straight and the cutends are to be square to the axis of the pipe.

4.9 Hydraulic test

4.9.1 Each length of pipe is to be tested at a hydrostaticpressure not less than 1,5 times the rated pressure of thepipe.

4.9.2 The test pressure is to be maintained for sufficienttime to permit proof and inspection. Unless otherwise agreed,the manufacturer’s certificate of satisfactory hydraulic test,endorsed by the Surveyor, will be accepted.


Component/Characteristic Rate of testingoperation

Resin/curing Gel time Two per shiftagent/catalyst Rate of consumption Continuous

Reinforcement Quality ContinuousWind angle ContinuousRate of consumption Continuous

Resin/ Ratio Continuousreinforcement

Pipe Post-cure:temperature of Continuousthe pipe in oven

Cure level At least eight per length

Dimensions Each length

Hydraulic Each lengthpressure test

Electrical Each length resistance (see Note)

Hydraulic At Surveyor’s bursting test discretion

Axial strength At Surveyor’sdiscretion

NOTEMeasurements of electrical resistance are only required on pipingwhere the operating conditions given in Pt 5, Ch 12,5.2.4 of theRules and Regulations of the Classification of Ships apply.

Table 14.4.1 Testing during manufacture of pipes

5.5.3 The responsibility for maintaining the required tolerances and making the necessary measurements restswith the Builder. Monitoring and random checking by theSurveyor does not absolve the Builder from this responsibility.

5.5.4 Where ultrasonic thickness gauges are used, theseare to be calibrated against an identical laminate (of measuredthickness) to that on which the thickness measurement is tobe carried out. If suitable pieces are not available from theconstruction, then a small sample of identical lay-up is to beprepared.

5.6 Material composition

5.6.1 The materials, prefabricated sections or compo-nents used are to be in accordance with the approvedconstruction documentation.

5.6.2 Where alternative materials are used, these are tobe of approved or accepted types and the manufacturer is todemonstrate to the Surveyor’s satisfaction, prior to their introduction, their suitability with respect to performance,otherwise full testing as appropriate will be required.

5.7 Material testing

5.7.1 Where so required, the material manufacturer is toprovide the purchaser with certificates of conformity for eachbatch of material supplied, indicating the relevant values specified in 5.7.4 to 5.7.8. These values are to comply withthose specified by the approved construction documentation.

5.7.2 Where the Builders do not conduct verification testing of the information indicated in 5.7.4 to 5.7.8, they areto ensure that copies of all certificates of conformity (whichmust indicate the actual tested values) are obtained for allbatches of materials received, and maintain accurate records.The Surveyor may at any time select a sample of a materialfor testing by an independent, where applicable, source andshould such tests result in the material failing to meet thespecification, then that batch will be rejected.

5.7.3 The following tests are to be carried out, whereapplicable, on receipt of any material:(a) The consignment is to be divided into its respective

batches and each batch is to be labelled accordingly.(b) Each batch is to be visually examined for conformity with

the batch number, visual quality and date of expiry.(c) Each batch is to be separately labelled and stored

separately.(d) Each unit, within the batch, is to be labelled with the

batch number.(e) Records are to be maintained of the above and these are

to be cross-referenced with the certificate of conformityfor the material and/or the Builder’s own test results.




Chapter 14Section 5

5.2 Design submission

5.2.1 The requirements for design submission aredetailed in the appropriate Part of the Rules which includesfull information on composite materials.

5.3 Construction

5.3.1 All constructions are to be carried out using materials approved or accepted by LR.

5.3.2 All materials are to be in accordance with theapproved construction documentation.

5.3.3 All batches of materials are to be provided withunique identifications by their manufacturers. Components areto be similarly identified.

5.3.4 No batch of material is to be used later than its dateof expiry.

5.3.5 The Builder is to ensure that all batches of materialsare used systematically and sequentially.

5.3.6 The Builder is to maintain, on a continuous basis,records of the amounts of resin and reinforcement used, inorder to ensure that the proportions remain within the limitsset in the construction documentation.

5.3.7 Records are to be kept of the sequence and orientation of the reinforcements.

5.3.8 The Builder is to ensure that each section of theconstruction is traceable to the batch or batches of materialused. The unique identifications required under 1.11.1 are tobe included on all relevant quality control documentation.

5.3.9 Any curing system used is to be demonstrated assuitable for the intended purpose and all pyrometric equipment is to be calibrated at least annually and adequaterecords maintained.

5.3.10 The post-curing temperature is to be controlled andrecorded by the attachment of suitably placed thermocouples.

5.4 Quality assurance

5.4.1 Where the Builder has a quality assurance system,this is to include the requirements of this Section.


5.5.1 Dimensions and tolerances are to conform to theapproved construction documentation.

5.5.2 The thicknesses of the laminates are, in general, tobe measured at not less than ten points, evenly distributedacross the surface. In the case of large sections, at least tenevenly distributed measurements are to be taken in bandsacross the width at maximum spacing of two metres along thelength.

(f) Type of fibre used.(g) Surface treatment and/or finish.

5.7.8 For core materials, the following properties are tobe recorded by the manufacturer for each batch:(a) Type of material.(b) Density.(c) Description (block, scrim mounted, grooved).(d) Thickness and tolerance.(e) Sheet/block dimensions.(f) Surface treatment.Together with the following mechanical properties:In the case of rigid foams:(g) Compressive strength (stress at maximum load) and

modulus of elasticity.(h) Core shear strength.In the case of end-grain balsa:(j) Tensile strength (stress at maximum load).(k) Compressive strength (stress at maximum load) and

modulus of elasticity.

5.7.9 During construction, tests are to be carried out onthe constituents and final product in accordance with Table 14.5.1.

5.7.10 The standards of acceptance for testing are thoselisted in the material manufacturer’s specification, approvedconstruction documentation or agreed quality control procedures as applicable.

5.7.11 Laminate fibre content is to be determined at therequest of the Surveyor, in particular where the thicknessmeasured does not correlate with the specified fibre content,by weight. This will, in general, result in additional reinforce-ment being required.

5.7.12 If the batch of resin or polymer, or the curing agent,or their ratio is changed, at least two additional measurementsof the gel time are to be carried out during each shift.


Chapter 14Section 5


5.7.4 For thermosetting resins, reinforced or otherwise,the resin manufacturer is to have determined, on samplestaken from each batch, at least the following:(a) All resins:

(i) Viscosity.(ii) Gel time.(iii) Filler content, where applicable.

(b) Polyester and vinylester resins:(i) Type (orthophthalic, isophthalic, etc.).(ii) Volatiles content.(iii) Acid value.

(c) Epoxide resins:(i) Free epoxide content.

(d) Phenolic resins:(i) Free phenol content.(ii) Free formaldehyde content.

5.7.5 For thermoplastics, the polymer manufacturer isto have made the following measurements on samples takenfrom each batch:(a) Melting point.(b) Melt flow index.(c) Density.(d) Filler/pigment content, where applicable.(e) Tensile stress at yield and break.(f) Tensile strain at yield and break.

5.7.6 Where the resin or polymer manufacturer mixesbatches, both the original batches and the mixed batch areto be tested in accordance with 5.7.4 or 5.7.5 as appropriate.The mixed batch is then to be given a unique batch number.

5.7.7 For reinforcements, the material manufacturer is tohave recorded, where applicable, the following for each batchof material:(a) Tex of yarn(s) or roving(s).(b) Ends per 100 mm in all reinforcement orientations.(c) Weight per square metre.(d) Binder/size content.(e) Stitch type and count.


Table 14.5.1 Testing during construction

Component/operation Characteristic Rate of testing

Resin/curing agent/catalyst Gel time Two per shift

Rate of consumption Continuous

Reinforcement Quality Continuous

Orientation Continuous

Rate of consumption Continuous

Resin/reinforcement Ratio Continuous

Construction Temperature during cure/post cure Continuous

Dimensions Continuous against approved constructiondocumentation

Cure level (Barcol) against resin At least one per square metremanufacturer’s specification

Laminate thickness Continuous against material usage andapproved construction documentation(see also 5.5.2 to 5.5.4)

Laminate fibre content At the Surveyor’s request (see 5.7.11)

5.12 Closed cell foams for core construction basedon PVC or polyurethane

5.12.1 Table 14.5.6 gives minimum values for closed cellforms for core construction based on PVC or polyurethane.

5.12.2 Other types of foam will be subjected to individualconsideration. A minimum core shear strength of 0,5 N/mm2

is to be achieved.

5.13 End-grain balsa

5.13.1 Table 14.5.7 gives the minimum property require-ment for end-grain balsa.

5.14 Synthetic chocking compounds

5.14.1 After 1000 hours the chocking resin must bestabilised and maximum creep is to be less than or equal to0,2 per cent.




Chapter 14Section 5

Table 14.5.2 Gel coat resins, minimum propertyvalues

Properties Minimum value

Tensile strength (stress at maximumload) 40 N/mm2

Tensile stress at break 40 N/mm2

Tensile strain at maximum load 2,5%

Modulus of elasticity in tension As measured

Flexural strength (stress at maximumload) 80 N/mm2

Modulus of elasticity in flexure As measured

Barcol hardness As measured at full cure

Water absorption 70 mg (max)

Table 14.5.3 Laminating resins, minimum propertyvalues


Tensile strength (stress at maximumload) 40 N/mm2

Tensile stress at break 40 N/mm2

Tensile strain at maximum load 2,0%

Modulus of elasticity in tension As measured

Barcol hardness As measured at full cure

Temperature of deflection under 55°Cload

NOTEThese minimum values are for the recommended glass contentby weight of 0,3.


5.8.1 All constructional mouldings and any componentsare to be visually examined and are to be free from surfacedefects and blemishes.

5.9 Repair procedure

5.9.1 Repairs of minor cosmetic blemishes are permittedproviding that these are brought to the attention of theSurveyor.

5.9.2 A repair procedure for these minor blemishes is tobe included in the agreed quality control procedures.

5.9.3 Structural repairs are subject to individual consid-eration and full written details must be approved by the planapproval office prior to introduction.

5.10 Material identification

5.10.1 Records of the construction are to be kept in sucha manner that traceability of all the component materials usedis ensured. The Surveyor is to be given full facilities for tracing the material’s origin when required.

5.10.2 Small representative samples of each batch ofmaterial are to be retained, these being suitably labelled toensure traceability.

5.10.3 When so requested by the Surveyor, the Builder isto provide copies of all test data and/or manufacturers’ certificates of conformity appertaining to any material used.

5.11 Minimum tested requirements for materialapproval

5.11.1 This Section provides the minimum property valuesrequired of a material for approval or acceptance by LR andare applicable to materials cured under ambient conditions.

5.11.2 Gel coat resins. When the cast resin is testedaccording to the requirements of 2.3, Table 14.5.2 gives theminimum values for the respective properties.

5.11.3 Laminating resins. When tested according to therequirements of 2.3 and 2.4, Tables 14.5.3 and 14.5.4 givethe minimum properties for the cast resin and chopped strandmat laminate respectively.

5.11.4 When tested to the requirements of 2.4 for reinforcements, Table 14.5.5 gives the minimum properties forlaminates.

5.11.5 Alternatively, materials may be approved by use ofthe actual tested values whereby the approval value shallequal the mean of the tested values minus twice the standarddeviation of a minimum of five tested values.

5.14.2 Compliance with 5.14.1 is to be demonstrated atthe time of chocking compound approval for a specifiedcure/post-cure schedule. The Izod, barcol, compression, andwater and oil absorption are additionally to be determined forthe creep tested cure/post cure schedule.

5.14.3 Confirmation of creep, barcol and compression willbe required for cure/post-cure conditions which differ fromthose shown on the product approval certificate.

5.15 Other materials

5.15.1 All other materials will be subject to special consideration.


Chapter 14Section 5



Table 14.5.4 Laminating resins, minimum valuesfor properties for CSM laminate at 0,3 glass fraction by weight


Tensile strength (stress at maximum 90 N/mm2

load)

Secant modulus at 0,25% and 0,5% 6,9 kN/mm2

strain respectively

Compressive strength (stress at 125 N/mm2

maximum load)

Compressive modulus 6,4 kN/mm2

Flexural strength (stress at maximum 160 N/mm2

load)

Modulus of elasticity in flexure 5,7 kN/mm2

Apparent interlaminar shear 18 N/mm2

strength (see Note)

Fibre content As measured (0,3)

Water absorption 70 mg (max)

NOTEApplicable only to the special test for environmental control resins.

Table 14.5.5 Laminates, minimum property requirements

Material type Property Value

Chopped strand mat Tensile strength (stress at maximum load) (N/mm2) 200Gc + 30

Modulus of elasticity in tension (kN/mm2) 15Gc + 2,4

Bi-directional reinforcement Tensile strength (stress at maximum load) (N/mm2) 400Gc – 10

Modulus of elasticity in tension (kN/mm2) 30Gc – 0,5

Uni-directional reinforcement Tensile strength (stress at maximum load) (N/mm2) 1800Gc2 – 1400Gc + 510

Modulus of elasticity in tension (kN/mm2) 130Gc2 – 114Gc + 39

Chopped strand mat Flexural (stress at maximum load) (N/mm2) 502Gc2 + 114,6

Modulus of elasticity in flexure (kN/mm2) 33,4Gc2 + 2,7

All Flexural strength (stress at maximum load) (N/mm2) 502Gc2 + 106,8

Modulus of elasticity in flexure (kN/mm2) 33,4Gc2 + 2,2

Compressive strength (stress at maximum load) (N/mm2) 150Gc + 72

Compressive modulus (kN/mm2) 40Gc – 6

Interlaminar shear strength (N/mm2) 22 – 13,5Gc (min 15)

Water absorption (mg) 70 (maximum)

Glass content (% by weight) As measured

NOTES1. After water immersion, the values shall be a minimum of 75% of the above.2. Where materials have reinforcement in more than two directions, the requirement will be subject to individual consideration dependent on

the construction.3. Gc = glass fraction by weight.




Chapter 14Section 5

Table 14.5.6 Minimum characteristics and mechanical properties of rigid expanded foams at 20°C

Apparent Strength (stress at maximum load) (N/mm2) Modulus of elasticity (N/mm2)Material density

kg/m3 Tensile Compressive Shear Compressive Shear

Polyurethane 960,85 0,60 0,50 17,20 8,50

Polyvinylchloride 60

Strength (stress at maximum load)(N/mm2) Compressive modulus

of elasticity (N/mm2) ShearApparent Compressive Tensile modulus density of elasticity(kg/m3) Direction of stress Shear Direction of stress (N/mm2)

Parallel Perpendicular Parallel Perpendicular Parallel Perpendicular to grain to grain to grain to grain to grain to grain

96 5,0 0,35 9,00 0,44 1,10 2300 35,2 105

144 10,6 0,57 14,6 0,70 1,64 3900 67,8 129

176 12,8 0,68 20,5 0,80 2,00 5300 89,6 145

Table 14.5.7 Minimum characteristics and mechanical properties of end-grain balsa

© Lloyd’s Register Group Limited 2014Published by Lloyd’s Register Group Limited

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